The side rails tie everything together.  The part is fairly simple to make, but precision is critical to alignment of the other parts.

The side rails are constructed of 2x4 lumber.  You'll need two side rails for each rack level you build.  The length is determined by the cage box length using the calculation from line number 15 of your Measurement Worksheet.  A 1/4 inch wide, 1/4 inch deep groove is cut into each side rail to accept the peg board panel top.  This groove aligns perpendicular to the 1/4 inch groove cut in the cross rails at both the front and back.  This alignment provides a seat for the peg board panel top and locks it into place.

Click picture for a larger view

Review the diagrams, notes & demonstration videos for the construction of this part.

Use cage box length calculations to determine the length of the side rails (line 15 of your worksheet).  For information on making cage box measurements see the Measurement section.

Measure and cut the side rails to length.

To cut the groove you may use a router, dado head cutter, or a normal table saw.

To cut the groove using a router, use a 1/4 inch straight bit.  Set the depth to 1/4 inch and set the fence so that the edge of the blade closest to the front of the router table measures exactly 1 3/16 inches from the closest edge of the side rail to be routed.  You may also use a dado head cutter to make this groove.  Set the dado blade width to 1/4 inch, and set the height of the blade to 1/4 inch.  Set the fence such that the closest edge (to you) of the blade is exactly 1 3/16 inches from the closest (to you) edge of the side rail to be cut.

Because a normal table saw blade removes about 1/8 inch of material, you may also use a normal blade to cut the groove by making two passes and moving the fence 1/8 inch between passes.  You must still make sure that the top edge of the groove measures exactly 1 3/16 inches from the edge of the cross rail.

This diagram shows how the side rails should align with the cross rails and the support feet.  Each corner aligns the same way and allows for the insertion of the peg board panel that acts as the top for your cage boxes.  

Click here for a picture of the corner assembly!