Projects -- DEC Module Storage Shelves Project -- 2008 09 01

Having over 1,000 DEC Modules lying in various boxes, I decided it was time to create some kind of brilliant organizational structure for them. Having just moved into our new home with a huge, walkout basement, the opportunities were wide open.

The IKEA Factor

IKEA sells these plastic, ribbed sheets that are to be nominally used as "CD Holders". It's the "INREDA" product, and costs about CAD$8. One day when I was there, I looked at it and thought to myself, "Hmmmm... I wonder if that will fit a DEC Module?" So I bought one, and sure enough, it fit perfectly! (Note that there's also an INREDA DVD holder -- the ribs are further apart than on the CD holder product; I don't recommend that one.) Each length of ribbing holds 24 CDs. (If Google can build their servers out of LEGO, surely I can build my storage racks out of IKEA?)

Ideal

Doing a little PowerPoint, I designed this initial layout. In order to keep it somewhat modular, there are four single-high module shelving units (each being a 6x3 sub-unit). This way I can build something that I can carry and move around easily. The double-highs are 5x2 and the quads are 3x2. These quantities are based on the number of cards I have, with about 20% expansion capacity. The red shelves are wood supports, so this takes the available capacity down from 24 to 22 (I designed in extra shelf supports for the quad high cards in the middle just in case). Note that the dimensions given on the PowerPoint are approximate (I wanted to get an idea of how big this thing would be). Final dimensions will be posted once I complete the project.

Here's an approximate cost breakdown:

Shelving Unit	INREDAs	Modules	#8 x 1" screws	Lumber (estim.)
Singles	36	1584	336	1746" x 6" (73 sq ft)
Doubles	5	220	50	336" x 6" (14 sq ft)
Quads	6	126	86	392" x 12" (33 sq ft)
Totals	47	1930	472	120 sq ft (4 sheets 8' x 4')
Costs	$376	(priceless)	$20	$80

The project total is $476, so I'm going to budget $600.

Cutting to Size

The IKEA INREDA is 4x the size of what I need (for single and double high modules; for quads it's only 2x the size, because quad modules are much deeper). So, I simply cut it into four pieces. This is a bit of a pain in the ass. I tried cutting it with an electric hand saw, but that left too many jagged edges that had to be filed down (and even then I wasn't completely happy with it.)

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NOTE added 20090101 -- it turns out that when you populate it with modules, you don't notice the jagged edges, so this approach is fine after all!]

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First Row

In this diagram, you can see the first row of the module storage unit being assembled. I used #8 1" wood-screws to hold the individual supports together. By tightening the screws, it also ended up holding the ribs of the ends together.

Note that cutting an 8' x 4' sheet of plywood into 6" strips is going to result in 7 strips of 6" and 1 strip of around 5" (because it's not exactly 48" wide to begin with, and there's lossage when cutting). Therefore, I've used the thinner piece as the spacer. In the current design, the spacers are shortened anyway to be the depth of the 1/4 INREDA (4 7/8"), rather than 6". The thickness of plywood I'm using (5/8") tends to be warped. Face the plywood so that the warp is bulging up -- gravity will fix it. Finally, the two screws that hold the facing pieces of supports should be screwed in so that you can do it from the "outside" edge rather than the inside edge.