I'm hoping to build a 10-bin 28qt rack ASAP.

It works out so that I should be able to get all 10 shelves out of one sheet of melamine. So HOPEFULLY that part will only cost me $30 + taxes. So a couple questions:

1) For the sides I was either going to use (4) 2" x 4"s. BUT they're pretty bulky and ugly. Would it be an alright idea to use (4) 1" x 3"s? Would that be able to support the weight of (10) 24" x 17" melamine shelves or would it be too flimsy?

2) Should I use 1/2" melamine or is 5/8"s better?

3) Do I need to worry about any bowing with a shelf of only 17" x 24"?

I am not going to be enclosing the sides of the rack to a) cut down on weight, and b) cut down on costs. If i can get this done with 1 sheet of melamine I'll be happier than a pig in...you know.

I'm also going to use a separate piece of 4" flexwatt on each shelf and wire them in parallel. I don't want to weave 1 long piece of flexwatt between the shelves as that would just waste $ on heating the flexwatt that's touching open air. Sooo more questions:

4) What increments can I cut the 4" flexwatt in? I've heard that you can cut on the black lines, but you need to insulate it. What do I do this with? Does the silver foil tape work as insulation or do I need to insulate it and then secure it down with the foil tape?

5) Do racks without enclosed sides waste $ on heating? Like I said I'm going to have the flexwatt in such a way that all pieces of it are covered by the tub being heated, so I hope that is as effective as having closed sides.

Hmmm I think that's all my questions, thanks for anybody that can help! I will post photos once this is done. (Hopefully early November)