Perfect for Home Labs – More at darkrym.com

Build your own compact and modular mini server rack using 2020 aluminium extrusion. This guide will walk you through the parts, tools, and steps needed to assemble a rack suitable for home labs or networking gear.

Parts List

(Links are Australian, but you get the idea!)

Tools Required

• Mitre saw (suitable for aluminium)
• Allen key set
• Measuring tape
• Marker or pencil

Aluminium Extrusion Cut List

Measure and cut your 800mm 2020 extrusions down to:

• 4 × 160mm – Depth
• 4 × 218mm – Width
• 4 × Height, calculated as:
  Height = (45mm × Desired Rack Units) + 40mm
  e.g. for 6U: (45 × 6) + 40 = 310mm

Aluminium can be cut cleanly with a standard mitre saw.

Assembly Instructions

1. Assemble Frame

• Form top and bottom rectangles with 2× width (218mm) and 2× depth (160mm) extrusions.
• Use the corner brackets to secure each corner.
• Attach the vertical height extrusions to the four corners of one rectangle, then attach the other rectangle to complete the frame.

2. Insert Spring Nuts

• Insert M5 spring-loaded nuts into the extrusion channels at an angle until they “click” into place.
• Slide them to the desired height to mount brackets, shelves, or other accessories.

3. Install Components

Mount your accessories using M5 × 8mm bolts and T-nuts:

• Rack shelves
• Mini ITX mount
• Drive bay
• Patch panel
• Power rail
• Custom mounts (e.g. for Dell 7070 or HP ProDesk)

4. Optional Add-ons

• Mount cooling fans or mesh panels to sides/back.
• Add rubber feet or small castors for mobility.
• Paint or vinyl-wrap the frame for aesthetics.

Tips & Notes

• Keep at least 2-3U free for airflow and future additions.
• Preload extra spring nuts into the frame before full assembly to save time later.
• Cable management can be done using adhesive clips, zip ties, or printed brackets.

My Racks Layout (16U Rack)

Front

Rear