Console Desk Design & Build (Update #2)

So... I started out about a month ago trying to figure out what to do with a couple of rack mount mixers and some rack effects... I started by drawing out a pair of squares in Sketchup in the size of my mixers and then worked out from there. I drew about 20 different versions from dual rack width designs to the current 4 rack width design. I wanted something that was relatively inexpensive to build and rigid without excessive weight. I also wanted the top of the console to be approximate table height and the shelf on the back should be wide enough and deep enough to support several sets of monitor speakers and video monitors as well as have some spare space for expansion. along the way I also realized I'd like a couple of rack units for my PC and ADAT recorders and power amps etc. So I designed a couple of 10U rack units on casters that were deep enough to support the console desk and be mobile so I could move it around to work on wiring etc... I also thought about at least one of the racks being enclosed enough to keep the noise down from the PC and tape units with low noise fans and some ducting to act somewhat as an iso box. [UPDATE] Isolation racks updated in attached Sketchup file and in the followup post. I'm including here some sketchup drawings and a couple of photos of the desk in progress... The sketchup file has both the desk and rack units to scale so if you feel inclined to build one simply explode the components and groups down into individual parts (each board or object like a caster or rail is a group) and then use each part as a guide. its pretty straight forward to add dimensions and print. I recommend a cardboard template for the end and middle sections rather than trying to draw each by hand... The rails are Middle Atlantic brand rails - RRF10 and RRF4. the lumber is 12mm (15/32") plywood with a 2x4 brace in the desk. The casters are 4" wheels with swivels. Woodstock International @ Amazon - H0679 and H0680. In my case I'm using a light wash of medium gray but obviously you could finish it however you feel inclined... I did it to reduce distractions and it covers a bunch of mistakes :-) if you are capable of 1/64" precision cuts you're probably going to want to stain it with something nice... ;-) The desk is designed to have the parts interlock to form a square and rigid desk with minimal amounts of wood. The desk weighs around 75lbs with the rails and requires 2 sheets of 4'x8'x15/32" plywood. I recommend using a table saw and a router to cut for clean edges and cut-outs respectively. I used a power hand saw with a 60 tooth fine cut blade, a hand saw, a 1/2" wood chisel. Investing in a large sheetrock square is definitely worthwhile as well as carefully measuring everything (twice) before cutting... I used 1 1/4" screws into pre-drilled 1/8" holes. I had started to wood glue it but as I added parts and things got stronger and tighter I didn't bother gluing the inside panels. Seems to be fine without glue. layout, cut and assembly took about 12 hours over 2 days. I'll be working on the racks this weekend and will keep you posted.... disclaimer: this design is NOT based on any commercial products. This is not a copy of some other product, but is the result of many hours playing around with the design and configuration. Feel free to use this design however you see fit, but there is no warranty implied; use at your own risk...

[UPDATE] finally have it assembled... I found a set of spring-loaded retractable latches to use to pull the doors shut against the Mr Frost 1/4" rubber window seal strips. I used a pair of 3/32" polycarbonate windows on the front door, sealed with some clear silicone caulk. The rear door has a pair of rubber tubes touching each other which mostly acts to seal the cables coming out of the box. Still needs some more -something- because there are small gaps when the snakes for the ADATs come through... The overall air flow through the box seems good, if you block the air intake on the bottom you can hear the fan struggle a bit with the resulting vacuum, not a perfect seal but decent. The noise level (subjectively) is much less than with the doors open and the ADATs running so I think in that regard the box is working. I used a section of heavy foam rubber to wrap around the fan to hold it in place. This has the benefit of isolating the fan and also sealing air gaps around it. The fan noise is still higher than I like it. Maybe putting the fan inside and pushing out would make it quieter. Maybe using a short section of 6" duct tube would silence it more. The photos show the boxes (prior to being dusted :-) [UPDATE] in keeping with the KISS principle, I realized that the early design was not going to be workable because of the potential for air gaps as well as maintenance on the fan. I've updated the design and am off to the supply store for another piece of plywood (I forgot I need 4 side panels not 2 plus need to recut the rear doors...) and some additional hardware I forgot yesterday... :-) this weekends project is to build the 10U rack cases. I've decided to build them as isolation cases. In the rack case where I have the ADAT recorders and my PC, I plan on using rubber grommets and spacers to help reduce vibration transfer from the fan and the devices. I'm thinking that if the units are isolated from contacting the case directly it may help. The air flow is through 2 boxes on the back door. basically a long U shaped box with roughly the same area as the fan. The fan is a 4" AC fan with a rated noise level of 25db and about 50CFM which (in theory) should cycle the air in the box about once every 10 seconds. probably need to play around with getting the flow within the box to be most effective. The boxes will be lined with something to absorb and otherwise reduce sound transfer. the doors will have some sort of light rubber gasket and some magnetic latch to keep the box sealed. the slot between the 2 boxes is where the cables pass through. the idea here is to wedge a large heavy foam block between the two boxes and slice through it. This should allow the cables to pass-through and be sealed from air gaps. might need some bracket or something to keep the cable properly spaced and supported. dunno. the attached Sketchup file has the case to scale. It may change slightly once I start building it and decide on any changes or need to make changes but here it is... I'll post photos later this weekend with the construction. The fans are on order and will probably not arrive until next week but once I have the cabinets fully loaded I'll try to do some sound level checking to see how much (or not) these things reduce the recorder and PC noises...

good banch and good idea for maintaing accessories . :yahoo: :shot: