Test run for PVC cage. DUW

So I have decided to make some PVC cages for myself instead of buying them. I figured I could save some serious money after building 5 or 6 of them, so I have planned and researched and finally came up with a good idea of what I wanted. No surprise, it looks a whole lot like the manufactured ones out there. First I drafted up some plans and went to work making a jig that I could use over and over again. Basically I wanted something to hold the plastic while I heated it up and bent the corners, so I came up with a box made of MDF with rounded corners and a system of braces built in to hold the plastic in place while I bend it. It ended up working pretty well for the test run, though there are some adjustments to be made. I made another jig for cutting the door but I didn't like the end result (it was about 1/8 inch off...) so I will be building another jig for the next test. Anyway, after I get the kinks worked out, I will be able to build 3' X 2' X 1' cages with clear doors and good hardware with flexwatt heat for under 100 bucks each! That's LESS THAN HALF of what I would pay for the cage if I ordered it! Plus, it gives me something to tinker with while my snakes are growing up! Let me know what you think!

Starting out by securing Expanded PVC in jig.
http://i82.photobucket.com/albums/j2...eyce/Step1.jpg

First bend made and second side secured in brace.
http://i82.photobucket.com/albums/j2...eyce/Step2.jpg

Bending the next corner.
http://i82.photobucket.com/albums/j2...eyce/Step4.jpg

My girlfriend doing a little bending with the Bosch heat gun.
http://i82.photobucket.com/albums/j2...eyce/Step5.jpg

The cage all bent up and ready to remove from the jig.
http://i82.photobucket.com/albums/j2...eyce/Step6.jpg

The cage, removed from the jig.
http://i82.photobucket.com/albums/j2...eyce/Step7.jpg

Sides installed.
http://i82.photobucket.com/albums/j2...eyce/Step8.jpg

Finished cage, without doors, heat, etc...
http://i82.photobucket.com/albums/j266/harveyce/Box.jpg

:O

WOW. Looks great

that looks like a lot of work!

Looks good!! I love working with the XPVC for racks, it's so nice but it's just so expensive unless you're buying large quantities. I have a few cages that I've built from 3/4" melamine that are great except that they weigh as much as a horse. I've been thinking of replacing them with plastic cages if I can build them myself for a reasonable price, so if you don't mind, I got a few questions for ya:

What thickness of material did you use?
Did you use a jig or template to cut out the side pieces?
Did you use a router to cut the material in the jig?
How did you glue the side pieces on uniformly?
What door hardware are you going to use?

Once again, great job. Post pics when you get 'em up and running.

-Evan

Quote:

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Originally Posted by Evan Jamison

Looks good!! I love working with the XPVC for racks, it's so nice but it's just so expensive unless you're buying large quantities. I have a few cages that I've built from 3/4" melamine that are great except that they weigh as much as a horse. I've been thinking of replacing them with plastic cages if I can build them myself for a reasonable price, so if you don't mind, I got a few questions for ya:

What thickness of material did you use?
Did you use a jig or template to cut out the side pieces?
Did you use a router to cut the material in the jig?
How did you glue the side pieces on uniformly?
What door hardware are you going to use?

Once again, great job. Post pics when you get 'em up and running.

-Evan

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I used 6mm, which is about 1/4 inch. For the sides, I basically measured and ripped the side with a table saw after I took the cage out of the main jig, then rounded the corners with a router. You could use a jigsaw to round the corners as well. The sides sit in a dado slot that I cut in the main part of the cage before I bent it. I used a dado blade set at 1/4 inch to make the cut very close to the edge of the material. Here's a pic of that...
http://i82.photobucket.com/albums/j266/harveyce/Cut.jpg
I did use a router to cut the door hole, but I have to make a more accurate jig for the next run, it was a little off and I want it to be more accurate... I used regular strength clear PVC glue for the joints, but I think I might try something a little stronger next time. As for hardware, I looked EVERYWHERE for something that I liked and finally found this web site Monroe Engineering but have not yet picked just which hinge I want to use. The latches will come from Sierra Pacific. I haven't figured out yet how I will vent the cage, but most likely I will either just gap the door a little or router thin slots in the sides.

Evan, one more idea.... If I can get these cages going pretty good, maybe we could do a little trading...

Thanks for the info! That dado cut was a great idea. On my wooden cages I cut a rabbet on the rear inside edge of the top, bottom and side pieces, and the back piece fits in nice and flush. I wonder if you could do the same thing on yours so the sides are flush instead of set back a bit. Either way it gives a lot of strength to the cage. Thanks for the links too.

Quote:

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Originally Posted by Wallbanger

Evan, one more idea.... If I can get these cages going pretty good, maybe we could do a little trading...

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Definitely a possibility if I don't get around to making any in the near future (which is likely :D ) Be sure to post some pics and let me know when you have a few completed.

-Evan

Wow! I am impressed!!!! Very nicely done!

wow that's great work.

That came out very nice; I too am a big fan of making things yourself instead of paying others.. nice job! I wonder if you could make racks in a similar manner?