Expanded PVC rack project

For a while I have wanted to build a rack out of plastic to see how it would come out. I have worked with Melamine and will never do it again. It was so heavy that I had to leave it when I moved out of my last place. I had a bunch of approx. 32qt boxes sitting around from the Melamine rack and after seeing a great thread on another forum decided to give it a go. Full credit goes to Gerry from Ssscales for the design and my buddy Phil for helping me figure out the cuts since I am terrible at that math stuff! I found 1/2" expanded PVC from a local supplier for $110 for a 4 x 8 sheet. They made the cuts for me for an additional $10. Here it is!

The top shelf and the 4 legs
http://www.glassreptiles.com/pictures/2008/DSC03940.JPG

A couple shelves done!
http://www.glassreptiles.com/pictures/2008/DSC03942.JPG

All the shelves done!
http://www.glassreptiles.com/pictures/2008/DSC03943.JPG

The back piece. I used 2 strips of 3" flexwatt for back heat
http://www.glassreptiles.com/pictures/2008/DSC03944.JPG

Then I wired them up. I chose wire them separately.
http://www.glassreptiles.com/pictures/2008/DSC03945.JPG

Here it is, done with boxes
http://www.glassreptiles.com/pictures/2008/DSC03946.JPG

A shot of a shelf with the heat tape at the back
http://www.glassreptiles.com/pictures/2008/DSC03947.JPG

The always exciting side view!
http://www.glassreptiles.com/pictures/2008/DSC03948.JPG

I liked working with the material and while not as cheap as Melamine, it's lightweight and cheaper than buying a prebuilt rack system. It's certainly not the amazing craftsmanship of an RBI rack but it suits my needs. Some things to consider when working with 1/2" expanded PVC. It scratches pretty easily. Not sure if this matters for anyone, it didn't for me. It's soft material so be gentle when drilling and screwing (I'll leave that comment alone now). Make sure you use a spacer when putting in the levels. I used what I think is a 1/8" piece of mason board. At least that is what I think Phil called it. Maybe he can post what it is. Anyway, that's that. It took less than 2.5 hours from start to finish and the total cost was:

$110 1/2" expanded PVC sheet
$10 cuts
$16 heat tape (might have been a few bucks less)
I had the boxes but 32qt boxes are pretty cheap if you use Sterilite.
$6 Box of 1 1/2" coarse drywall screws

How hard was it to get the side screws dead straight into the shelves?

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Originally Posted by Patrick Long

How hard was it to get the side screws dead straight into the shelves?

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For someone who is good with tools, probably pretty easy. :D

Actually, it's harder to get the legs screwed on. The shelves are pretty easy because they are sitting on a tub and stay even. I fouled up a few early on but got the hang of it by the end!

Because that does look very clean. There is a sign shop here in town, Im thinkin that this just might be worth the while.

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Originally Posted by Patrick Long

Because that does look very clean. There is a sign shop here in town, Im thinkin that this just might be worth the while.

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You're going to get hosed getting it from a sign shop. Cut out the middle man and start calling plastics companies. I did a google search for plastic sheets nj and it gave me a list of companies. I called each one and asked for pricing on 4x8 sheets of black 1/2" xpvc. Some have multiple brands. Ask for the cheapest one. They are all pretty much the same thing. I think Gerry had posted that the average price was $90-$120. If you pay more than that you're getting the shaft. Good luck!

looks great! i've been kicking around the idea of building with plastic.

how much material did you have left over? is there enough to enclose sides and back?

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Originally Posted by twh

looks great! i've been kicking around the idea of building with plastic.

how much material did you have left over? is there enough to enclose sides and back?

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Thanks Tim! Definitely not. We maximized the cuts and ended up with nothing but scraps (which I didn't take with me). You'll need part of a second sheet to enclose the back and sides fully.

Nice rack, Jamie. I've been googling plastic companies in IL, but I'm still looking for a place with decently proced sheets.

Pat, Ryobi has an affordable 14.4v drill that has a built in bubble level. It's been a lifesaver for the last couple of racks I built. No more screws shooting out the tops of the shelves.

wow thats AWESOME!

i NEED to get my butt in gear and start looking for this stuff. I have all the dang tools available at my disposal.....

Thanks Jake! I definitely need one of those drills if I'm going to build more of these!
Thanks Alicia! Let me know if I can help you find a distributor!