One thing that has been lacking since the first build of the rack is ventilation. With both sets of doors closed, the inside can get quite warm, especially when iron is turned on. Not any more though, having just completed the installation of 2 active ventilation zones, lighting and a low voltage power supply system complete with rack-mount control panel.

Air is drawn in at the bottom of the rack by 5 quiet 80mm 12v fans, positioned behind a perforated 2U panel inside the front panel of the base. The air is blown vertically into the cabinet from the bottom through a similar 1U perforated panel. Although the draught is barely noticeable, the difference it makes to temperatures at the front of the rack is significant.

With this ‘air curtain’ alone though, the back of the rack still gets very warm. To solve this I’ve installed a relatively huge 200mm ‘Big Boy’ fan into the newly-added top of the cabinet. This sucks out the warm air and dispenses it into the containing room. Together these fans keep the entire cabinet cool.

To power the fans I’ve used an old ATX power supply. In order to make replacement easy when the supply fails, no modifications have been made to it. Instead, I bought a 20-pin molex connector so that I could just plug the ATX connector straight into my system.

The PSU is connected to 4 switches that are mounted on a 1U blanking panel in the front of the rack. I wanted some fancy switches, so I splashed out on some nice chromed illuminated ones from China (via eBay). There’s one green DPDT switch, which switches the PSU on and off, and three blue SPDT switches which control power to the two fan systems and some lighting.

The lighting illuminates the front of the rack, and is there purely for decorative purposes. I had considered using cold-cathode tubes, but the seller that I got the switches from also sells strips of LEDs encased in a flexible transparent rubber-like substance. They are sold in various lengths, but I thought 96cm would be OK for what I wanted (at the time I bought it to experiment with, thinking that it could illuminate the wall behind my desk). This strip is now mounted on the left-hand front door.

I’ve finally gotten around to fixing the top to the rack cabinet. It’s made from the door of an old storage-only cabinet, which was actually a fridge/freezer cabinet from Ikea. The top has been cut into the correct proportions for a while, but has just sat cluttering my floor until now.

To allow the many cables to enter the cabinet a notch of approx 8cm square was cut out of one of the panels. These two panels could then be slid together without the need to disconnect any cabling already in place.

Unfortunately I’ve discovered that the top of the cabinet isn’t exactly square – it’s slightly warped, as the photo below shows when the top had been fixed. I’m not happy with this so at some point I’ll have to put some effort into correcting it. Next time I build a rack I’ll make the top and bottom in more of a similar manner, with a known square-angled piece on which to fit the timber supports.

The top currently has no ventilation, but that will change soon thanks to a lovely huge ‘Big Boy’ fan.

There are still a few finishing touches to be done, such as adding the top, adding the lock to the rear, mounting the new bolts to the front door, cutting out the bottom ventilation hole and adding some fans. Future modifications could include adding lighting and environmental monitoring/control.

Below is a photo log showing how it was done.

Phase 1 – Building the frame

The frame was constructed using 5 44×44x2400mm PSE timbers and 1 44×94x2400mm PSE timber to give strength at the base. Some small modifications had to be made to get the front rails installed (had to move one of the top cross-beams back).