Quote 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

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...

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.