Descriptions with Video Demonstrations

Start main frame assembly!

WARNING:  Be aware that the parts on this rack system can and will warp if exposed to excessive moisture.  If you plan for any part of this rack system to be exposed to water, this is the time (before assembly) to treat all your parts with a good wood sealer.  Check out the your local home improvement center to find the appropriate product.  Make sure you allow any wood treatment to dry well before housing any animals in your rack. Once you've done so, move on to the assembly below.

For each rack level you need 2 Cross Rails, 2 Side Rails, 4 Support Feet, 1 Cage Top Panel, a number of Box Rails (see Box Rails section for how to determine the number of box rails needed) and a number of Heat Tape Supports to equal the number of Box Rails in your rack system.

Begin by stacking the cross rails on top of the support feet.  Use two support feet, one on each end of the cross rail.  The groove in the cross rail should be facing down.

Now drill two pilot holes in each end of the cross rail.  The pilot holes help to prevent the wood from splitting when screws are inserted.

Once pilot holes are drilled attach the cross rails to the support feet through the pilot holes using 2 inch wood screws.

Once you have two cross rails attached to support feet on both ends, turn them so that they are parallel to each other with their peg board panel grooves facing each other.  Add the side rails, lining up the grooves in the side rails with the grooves in the cross rails.  Clamp the entire assembly together using bar clamps.  Or if you don't have access to clamps use bricks or some other heavy object to keep it all together.

Square it up!

Measure & cut peg board panel top!

Mark the peg board using a tape measure.  Draw a line to use as a guide to make your cut or use a straight edge to guide the saw.  Cut the peg board panel top using a circular saw or a jig saw. 

Add peg board top to main frame!

Finish main frame assembly!

Now you're ready to permanently attach the side rails to tie the entire rack level together.  Drill pilot holes in each end of the side rail at an angle to the support feet.  Start the hole 1/2 to 1 inch from the end of the side rail.  Then attach the side rails to the support feet using 2 inch wood screws.  This drawing shows how the main frame should fit together.

Once you've attached the side rails to the support feet on the underside of the rack, turn the rack level over onto its feet.

Now attach the side rail to the cross rails, using the same method.  Drill pilot holes in each end of the side rail at an angle to the cross rails.  Start the hole 1/2 to 1 inch from the end of the side rail.  Then attach the side rails to the cross rails using 2 inch wood screws.

Attach box rails!

Turn the rack levels over and support them on each corner with wood blocks or bricks.

It is best to start from center and move outward when placing and attaching your box rails.  To find the center, measure with a tape measure the entire internal length of the cross rail and divide that length by two (use the online calculator link in the Measurement Worksheet section if you need assistance).  Once you have found the center point, mark it with a pencil.

Now that you have a center point you may start to lay out the box rails.  If the total number of box rails per rack level is an odd number, center a box rail directly on the center line.  If the total number of box rails per rack level is an even number, place a cage box on the center line and place your box rails to the side of it.  Use clamps to secure the box rails as you place them.  You'll attach them with screws later.

Measure the length of a cage box plus 1/4 inch between box rails.  This is only a place to start.  Once you've laid out two or three box rails, you'll stop and test to get the best fit.

Before testing leave the clamped box rails in place and turn the rack levels over on to their feet.  Move the clamp handles to the side if necessary and use a cage box to slide in and out of the rack level.  Make adjustments to the distance between one pair of box rails until the box slides the way you want it to slide.  Once you've produced the best fit, transfer that measurement to the distance between the remaining box rails.  Make sure that the measurement between box rails is the same on both ends of the box rails.  Rails that are not exactly parallel will not perform very well over time.

Make sure that you place the box rails that are routed on only one side on the ends of the rack level.

Once you're happy with the fit of the box rails and how they slide, you'll secure the box rails by drilling pilot holes and attaching them on each end to the cross rails with 2 inch wood screws.  Use two screws on each end spaced 1 to 1/1/2 inches apart.

Assemble Rack System Base!

Place the heat tape supports so that they align with the box rails above them (they should overlap the base rails by 1 inch on each end).  Remove the rack level, being careful to not move the base rails or the heat tape supports.  Nail or screw the heat tape supports into place.  You may want to use something heavy to keep the base rails in place while you attach the heat tape supports.

Next, attach the heat tape to the heat tape supports.  Use a method recommended by your heat tape manufacturer.  These may include silicon adhesive, electrical tape or some other method.  Make sure the tape is well-secured to the supports.

Turn the first (lowest) rack level upside down.  Flip the base rail assembly over with heat tape installed and place it on top of the support feet of the lowest rack level.  Be sure the corners are well-aligned.  Then attach the base rails to the rack level using 2-inch wood screws.

Turn the first rack level with base assembly over and you're prepared to stack up the remaining rack levels.

Stack & attach rack levels!

You may heat the rack system in a number of ways.  Each level may be heated independently.  One advantage to doing this is that you can heat only the levels you actually use which will save on power consumption.  Another advantage is that you may maintain different rack levels at different temperatures using different thermostats for each level or combination of levels.  A disadvantage to this method is that you'll need more equipment (heat tape plugs & clips, thermostats, etc.).  However, if you're caring for multiple species in the same rack system this may be the preferred option.

The other option is to heat the entire rack using one long strip of heat tape.  In this case you'll only need one set of heat tape clips and one cord/plug.  However, you'll have to wind the heat tape through the entire system, attaching one length at a time to the heat tape supports as you assemble the rack system.  The disadvantage to this method is that in order to disassemble or reconfigure the rack you'll have to remove the heat tape and re-install it when you put it back together.

If you intend to heat all rack levels the same with a single thermostat, but would like to have the flexibility to change configurations later on, you may plug the heat tape from each rack level into a power strip, and then plug the power strip into a thermostat.

Whatever method you choose, just make sure that the heating controller you use can handle the combined wattage of the length or lengths of heat tape attached to it.   

Once you've stacked the rack levels and installed the heat tape, secure them to each other using metal corner braces attached on the inside corners of each rack level.  It can be difficult to get enough leverage to attach these braces using a screw driver, so you may also use metal mending plates attached to the outside of the rack levels which will be much easier to attach.  Or you may attach the inside corner braces before stacking the rack levels by measuring the width of one 2X4 from the end of the cross rail.

Plug it in and Enjoy!

Important!  Never run heat tape without some kind of temperature controller! 

If you're heating the rack system with one long strip of heat tape you may plug it directly into the thermostat and set the temperature.  Just follow the thermostat's directions.

If you are heating the rack levels independently you may plug them all into one power strip and then plug the power strip into the thermostat.  Or you may plug different rack levels or groups of rack levels into different thermostats to maintain different temperature zones.  Be sure the thermostat can handle the combined wattage of all your heat tape.  Once it's all plugged in spend some time calibrating temperatures before housing animals in your rack.

Click for picture of finished rack system!

Now that you've completed the assembly process add the cage boxes, and step back to appreciate what you've done!

You now have a modular rack system, customized to meet your needs.  Not only can it meet today's needs but it can grow and change with your collection.  While you may only need 3 levels now.  You might need 10 in a couple of years.  When you're ready you can add to it.  

Although it can take time and effort to build one of these rack systems, think of the cost savings and years of good use you'll get out of it.

Use it Well!