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The cross rails are what the box rails and cage boxes "hang" on. They're not hard to make, but an eye for precision will provide the best result. The cross rails are constructed of 2X4 lumber. There are two cross rails per rack level, one at the front of the rack and one at the back of the rack. They are attached on their ends to the Support Feet and connected to each other front to back by the Side Rails. A groove is routed out of the cross rails that aligns perpendicular to the grooves in the side rails and allows the insertion of the Peg Board Panel cage top. The total length of your cross rail depends on the size of box you're using, the number of boxes you're using per level, and the number of box rails. The length of the cross rails is found in line number 13 of your Measurement Worksheet. Review the diagrams, notes & demonstration videos for the construction of this part. |
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| Use the
total measurement in line number 13 of your worksheet for your cross rail
length. You can see from the drawing above how the calculation takes
into consideration all the box rails, cage boxes and support feet when
determining the length of the cross rail.
For information on making cage box measurements see the Measurements section. |
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| Once you've calculated the length of the cross rails, measure them and cut them using a circular saw, miter saw, or table saw. |
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The only additional cut required on this part is a 1/4 inch high groove that's at least 1/2 inch wide which stops short of the end of the cross rail by 1/4 to 1/2 inch. The best way to make this cut is using a router equipped with a rabbeting bit with a ball bearing guide. You may use a router table or free-hand rout the groove. Use a bit with a blade that cuts to a depth of at least 1/2 inch. Set the bit to exactly 1/4 inch high. Check and recheck this measurement. |
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This diagram shows how the groove in the cross rails should align with the groove in the side rails. Each corner of the rack system aligns the same way and allows for the insertion of the peg board panel that acts as the top for your cage boxes. |
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You will need two Base Rails for your rack system. The Base Rails give additional stability to the rack and provide a mounting surface for heat tape supports which will carry the heat tape that provides warmth to the bottom rack level. These are constructed of 2x4 lumber and are cut to the same length as the cross rails (see line 23 of your worksheet). So while you are preparing your Cross Rails, cut two extra to be Base Rails. No other cuts are required to make this part. |
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