Planning a modular storage design

[WillAdams (William Adams (Carbide 3D))]

There have been a number of designs worked up for racks for the Storehouse Organizers from Harbor Freight — since I have:

• a bunch of 1x6s (nominal) from salvaged pallets
• three 0.25" x 3.5" x 48" (actual dimension) craft boards
• a bunch of 1/4" wooden dowels and misc. other hardware

I worked up a design in 3D:

which has a pretty simple cut-list:

• 5 side/back pieces — 0.75" x 5.5" x 31.5" (note that that last dimension may be varied based on how many organizers the rack will accommodate)
• 4 top/bottom pieces — 0.75" x 5.5" x 16.5" (note that two may be chamfered at their front corners
• 24 (this quantity is variable based on the size/number of organizers the rack will accommodate) runners — 0.25" x 1.375" x 10.25"

The parts are easily laid out in the file:

and exported as a DXF which may be opened in Carbide Create and the details of hardware and so forth worked out.

Two separate files will be needed since the top/bottom/side/back pieces have a different Stock Thickness than the runners.

The sides are doubled up with symmetrical layouts which accommodate the runners:

and the back parts will need some additional holes to secure the back:

When cutting, it will be necessary to mirror things, and adding a chamfer to the front pieces would be a nice aesthetic touch.

Adding dowels or biscuits to the parts to ensure alignment is an optional improvement.

Toolpaths for the runners are quite straight-forward:

(which will of course require workholding such that tabs are not necessary)

https://www.blockscad3d.com/community/projects/2128636

[WillAdams (William Adams (Carbide 3D))]

The balance of the parts are easily set up in a separate file.

Tops and bottoms are the same:

Except fronts will need to be chamfered — the easiest way to do that in Carbide Create is to use the Corner Tool:

and round two corners:

OK

Then use the Node Edit tool:

v

to convert the rounded-off corners into chamfers.

[WillAdams (William Adams (Carbide 3D))]

Since the Stock Height dimension will match the width of the stock, it will only be necessary to cut the ends of the boards. This is most easily done with a suitable set of Pocket toolpaths for geometry which matches the ends:

For the angles, draw a larger rectangle:

Then select all the geometry which describes the desired region:

and use the Region Builder tool:

Yes

Done

Delete what is no longer needed:

and add a circle:

and a closed polyline:

to extend the shape to ensure that the angle is fully cut:

Yes

Done

clean up again:

Select and copy-paste:

Mirror-horizontal:

and drag into alignment:

Then assign a Pocket Toolpath:

[WillAdams (William Adams (Carbide 3D))]

The unit for the racks is either 2.5" or 5" depending on whether one wants to accommodate a small or large organizer:

Adjust the number of units and the positions of the top/bottom holes as necessary for a given quantity.

The holes at the top/bottom for screws will be 1/8" and through the stock, while the holes for the runners will be 1/4" and only 1/2" deep (so as to not show on the outside).

[WillAdams (William Adams (Carbide 3D))]

Toolpaths for the sides are pretty obvious:

with the adjustment the holes along the edge for the back:

may be deleted when cutting the sides toward the front.

[WillAdams (William Adams (Carbide 3D))]

Tried to do this in “Layout Computer”:

Layout Computer

but no fractions, or control over butt orientation (other than rotating the piece) and no ability to add runners or shelf hole patterns or other features (that I have yet found).

[WillAdams (William Adams (Carbide 3D))]

Cut the parts:

and then assemble using suitable hardware and 1/4" wooden dowels.

[WillAdams (William Adams (Carbide 3D))]

Got started on assembly, but messed up, as-is inevitable when I violate one of my design tenets — parts should be symmetrical where feasible.

Made two lefts:

So recutting the parts to make a right, then hardware store for more dowels (or I’ll finally decide where to install that Lee Valley Dowel Plate…)…

For penance this evening, I’ll redesign the sides to be symmetrical.

[WillAdams (William Adams (Carbide 3D))]

A further issue, managed to install the runners upside down (see, should’ve been symmetrical).

Hopefully last issue, there’s a small tab as part of the mold which interferes with the fit — a reasonable solution might be to make a jig to guide a drill bit so that it can be drilled at the corner (so that there won’t be a sharp angle vulnerable to stress).

[WillAdams (William Adams (Carbide 3D))]

Or, just cut:

The chest fits on a moving dolly:

and things fit and work well enough.

A reworked version of the file will want to address:

• a bit more interior room on the width to make loading/unloading easier
• the runners should have an angle to match the uncut portion of the tab and a flat at the back to account for it — this will require a bit more space above each runner