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Super Compact Rolling Rackmount Setup


Michael Panfeld

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Took me about 6 months of design, testing, redesign, and testing, but wanted to share my build. I wanted to have something I can use on both a cart (Modified R12 Rock n Roller cart build pix coming in a week), or that I can take to a location via car, subway, or plane.  Its super compact and dense, but has all I need.

 

I started with a Gator Case G-Mix.  It has a 12U rackmount space that tilts.  I chose this over the similar SKB case, because it has a greater depth when closed and I needed that depth for the components.

 

To me, the case seemed a bit flimsy, so I modified it.  First, I cut to fit several 1/8 birch plywood panels and riveted them to the case sides and floor.  Birch plywood is super stiff and lightweight.  Cut some foam to lay on top.  I added a second set of hinges to carry the weight better.  I added aluminum bar stock to the outer case trim to stiffen the case.  1/4" x 1" across the bottom, drilling out the old rivets and replacing with thicker ones.  Similar on the top, but thinner stock.  The result was a much sturdier infrastructure, one that I am comfortable using to hold my gear.

 

Component pairings were chosen for size, function, and compatibility.  Rackmount components all came from Ebay.  Hardware from Home Depot.  Tools needed are a drill, screwdriver, riveter, and a file.

 

I purchased three 6" depth rackmount shelves from Navepoint (Model NPL-CS01).  The bottom shelf holds my 788T on top.  Underneath are my power solutions.  Power is all DIY, save for the Samlex DC-DC converter, a $25 Ebay find.  On the left are two power input panel mount plugs.  I used 4-pin ham radio plugs to match my current bag distro setup.  I installed two plugs so that I can hot swap batteries without powering down.  The plugs have a locating pin and are locking.  Power is routed from here to a control box mounted on the right side.  Control box has an easily reached fuse that glows red when blown.  Toggle switches control the power flow.  I set this up so that I can power from multiple sources.  I have several Lithium battery packs that were originally made for the Dalsa camera, all are 29.6 volts.  The larger ones have about 710 watts and the smaller ones are about 400 watts.  I can also use my smaller 12-13 volt bag setup batteries by bypassing the Samlex converter.  I also can power by plugging in the Lithium pack chargers (via AC) directly to the power input port, as a last resort. 

 

Power out goes to two places 1) BDS distro and 2) series of buck boards.  There are a three buck boards mounted in Radio Shack project boxes.  The Samlex converter spits out juice at 13.8, which is too hot for the Marshall monitors.  So I use the buck boards to bring it down to 12.0 volts.  It draws a lot of amps, so I split the load between a pair of these wired in parallel.  The third buck board brings the 13.8v down to 5v.  I needed 5V to power a pluggable USB charging port (so I can charge my iPhone) and, to power the receivers for my wireless feed to the Marshall monitors.  I use the Nyrius Pro wireless HDMI.  Transmitter plugs on the camera (if they allow me).  I can also accept SDI, etc via wire.  The buck boards also double as voltmeters and toggle between input voltage and output voltage.  Voltage is adjustable.  I have a watt meter as well so I can monitor my watts/amps/volts.

 

With the other two shelves, I built a storage box by riveting some sheet metal to one, sizing it for a 3U space.  I did not attach to the second shelf.  I covered all of the shelves with super thin 1/16" inch shelf liner that I purchased from Harbor Freight Tools.  The storage area can hold all of my transmitters, plug-ons, mics, lavs, Comtek, antennas, etc. 

 

Both the storage area and the power area are covered by doors.  Essentially, these are patch panel fillers mounted to rackmount hinges.  I used Racksonic 2U Rackmount Patch Panel Mounts (Part # 34-199952) and 2U/3U Flanged Steel Patch Panel Fillers.  I drilled and superglued magnets and a handle on the end opposite the hinge.  These are super strong and hold the door shut.  I used nylon spacers and longer rackmount screws so the panel, which is raised by the addition of the hinge on one side, lays parallel to the shelf when closed.  The screws are steel and their heads are aligned with the magnets.  It literally snaps.  I built and upholstered a super plush full length wrist rest and attached this to the power door.  My wrists rest there when I am mixing on the CL-8.

 

A tiltable Marshall rackmount dual monitor and a pair of Lectrosonics multicouplers loaded with 411's complete the structure.  When its all screwed together it has a solid feeling. 

 

I also built an antenna mast to carry the 4 sharkfins (for the multicouplers), two dipoles (for the wireless hops) and, when I get one, a Phase Right (for the Comtek).  I used simple 80/20 1" black anodized T-slot pieces cut to 18" long.  I drilled out the center holes a bit and super glued in magnets  on each piece so the two pieces snap together.  I also used four 3-hole T-nuts to align and then further strengthen the assembly.  I left two screws loose so that putting it together only requires me to tighten two screws.  I bought a few short spuds with 14/-20 threads from BHPhoto to mount the antennas. 

 

The antenna assembly is mounted to a Matthews telescoping pole with a baby spud on top.  That is screwed onto a homemade clamp that clamps to the case.  It can rise about 4 feet, which works well indoors.  When I am using this on a cart, I have a taller mast.  The two 80/20 pieces and the Matthews mast break down to 18" pieces that can either be mounted with Velcro underneath the Lectro multicoupler (in the space behind the Marshall monitors), or inside the storage box. 

 

I use a pair of Audio Ltd for my wireless camera hops.  These are velcro'd to the outside of the storage box.  On the top rear outside of the storage box I have a BDS distro for the 788 and Lectros.  Also mounted nearby is a secondary distro for the Wireless HDMI receivers, USB charging hub, and for the Marshall monitor power feed coming off of the buck boards.  I also have a Comtek velcro'd in this area.  To power the Comtek and the Audio Ltd's, all of which run on a 9v battery, I wired three QC Avionics 9 volt Battery Eliminators (http://www.ebay.com/itm/261224656811) to the BDS.

 

With everything up and running, it draws about 91 watts/hr.  I have a toggle switch to control power to the buck boards for the Marshall monitors, USB hub, and HDMI wireless receivers.  If I am not using those, I can shut that off and, the 788T, Lectros, hops and Comtek draw about 45 watts/hr.  So, full on, the two large battery packs will run me well into any overtime day.  One large pack will run me all day without monitors.  Small battery will run non-monitor package for short gigs. 

 

The whole thing weighs 62 lbs with all gear, radios, antennas, case, etc,.... and is a rolling case. Case weight is only 1/3 of that.  The stiffening barely added any weight.  In reality, if I was taking this on the subway I would probably hand carry the Schoeps in a small bag, perhaps with a few doo-dads like transpore etc.  I also do not have a solution for storing the sharkfins.  Those will be hand carried.  But, sling a boom pole over the shoulder, grab a battery, and I am good to go.  For bag work or if I am doing a 1-person sitdown interview, this is overkill and, I have a separate setup and gear for that. 

 

Oh contrary to most folks, I generally work off of a cart standing up during takes, sitting only during down periods.  So the ergonomics of the tiltable monitor, the position of the Lectros near eye level, the wrist rest below the CL-8 and at the level of my elbows was all thought out and tested.  If I can find a good fold-up kneeling chair, I may work on a lower platform.

 

Thanks for reading.  Appreciate any comments.

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Thank you for the thorough and informative write up of your unique case-based cart setup. Everything looks good except for the DC distro box which to my eye seems a little funky (in terms of choice of switches, using all those different surfaces of the box, etc.).

 

The above picture is one of the most interesting ones for me, clearly showing how you used the angled rack design of the Gator case and how it works for you because you like to mix while standing up.

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Thanks for the observations Jeff.  Indeed, when the 1st prototype came out in August that box was simpler and, housed a Pico Mini-ATX power supply.  That's a micro-computer power supply that gives you regulated 12v and 5v rails.  That worked fine with a 744 and 1 rack of Lectros.  When I upgraded to a 788 and added a 2nd rack of Lectros, it blew past the 6A limit of the supply.  I had to rethink my power options.  I repurposed the box, so it looks messy.

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Wow....  you really put some work into it....  but... It's GIGANTIC!!!   As long as it needs to be on a cart... for a stand of some sort... It is way to big...  It would probably not fit out that door in the photo.... 

The antenna array is also...... well... really big too.. 

 

  If you could somehow scale down the antenna set up, and get the main case to mount on a very small cart of some sort... You will be living large... and end up with a "more" compact set up...

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Thanks.  1st of all, that's not my cart set up.  I just happened to place that on the cart for the pix.  On a cart, I would not use that antenna mast attached to the back of the case.  Rather, it would be located on a pole centered on the end of my cart, so its width would be the length of the sharkfin, which is much narrower than the Rock n Roller cart it is sitting on.  If I needed to roll through a doorway, the case would be turned sideways so that the carts long axis and the case's long axis are in parallel.  Case is 21" wide.  Will go through any door.  Note that my cart build pix will go up next weekend.

 

Not sure if you noticed the last pick which shows the case looking like any other rolling luggage.  That's the whole setup in that case (sharkfins can be stored in lid).

 

The antenna mast itself breaks down small already.  Its even more compact if I unscrew the brass spuds.  See pic.  The setup looks big in the pic because the rack is tilted and the mast is attached to the back.  The case is only 21 x 25 x 10.5.  It will roll through any door, escalator, elevator, even go up stairs (carefully).  It can easily be checked on a plane (Although I would hand carry the 788 and mics/transmitters).

 

But when you suggest a smaller cart, you may be missing the point.  How about no cart at all.  I roll this on to a subway car, get off at a location, open up the case on a conference table (or whatever is there) or - simply keep it on the floor and mix while kneeling.  I do have to say that in DC, there is a lot of industrial gigs that are only a few hours long and a short Metro or taxi ride away. 

 

I have looked at a 2' x 4' foldup table from Home Depot that has adjustable heights.  It looks perfect, but I am still on the hunt for a foldup kneeling chair to match that.  

 

I have also looked at using the case lid as a table, making legs that stow in the case lid and screw into the lid when setup.  Again, that would best be paired with a kneeling chair.

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Look at RV stores for your folding table legs.....   They use them in the recreational vehicles all the time....  I actually bought them there before for the exact same thing.. 

 

I saw the last photo... It does get smaller...

 

 Beware... every crack in the sidewalk will rattle that cart to it's bones with the small urethane luggage wheels... I have a pull cart just like it and it is an issue...  especially with all the connections in your cart....  see if it's possible to get some larger wheels .... I think it will make it so much better to transport around...

 

If you take the subway to work, and only bring the cart in the photo.... you are my hero.... I would feel like the Emperor with no clothes...LOL..  all the power to Ya...

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