Telco Brackets for Data Center

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Hey Guys,Its been a while since I've posted some of my work.  My main business is owner of a small Infrastructure Cabling company. From time to time we end up having to fabricate custom items to complete our task at hand.This project was in a customers data center and required us to mount cable tray and patch panels above some existing server cabinets.  Since all the equipment was in place and active we could not touch any of it until a scheduled maintenance window.  So we had to have a solution that was quick and easy to install onsite during the scheduled work time.First we needed to mount some wire basket cable tray above the existing ladder rack to provide a pathway for some new fiber optic cables.  Then we had to mount a bracket to the existing ladder rack to support some existing cat6 patch panels and to accomodate the the new fiber optic patch panel.  The existing brackets did not allow for expansion.We fabricated some brackets that slid over 3/8" threaded rod to support the 2"x4" wire basket cable tray.  We used 1/2" Sch40 black pipe and some 1" x 1" x 1/8" angle.  I made two at first to see if the part worked and then made a jig to make 30 more.Used my bandsaw to cut the parts, and my syncrowave to weld them up.Installed tray bracket pics to follow-  Then the panel brackets will follow..... Attached ImagesBrianLincoln Mig 215Miller 211Victor Torch SetMiller Maxstar 200SDMiller Syncrowave 250DX Tig runnerMiller Trailblazer 302 running on LPMiller Extreme 12 VS SuitcaseEllis 1600 BandsawMiller xmt350 CC/CVLincoln Vantage 300
Reply:Here are the brackets and tray installed above the existing installation. Attached ImagesBrianLincoln Mig 215Miller 211Victor Torch SetMiller Maxstar 200SDMiller Syncrowave 250DX Tig runnerMiller Trailblazer 302 running on LPMiller Extreme 12 VS SuitcaseEllis 1600 BandsawMiller xmt350 CC/CVLincoln Vantage 300
Reply:Now for the panel brackets.Since I needed to maintain the proper spacing to be able to mount the panels, I purchased a few standard 19" wide equipment racks and cut them down to provide the necessary mounting area for the panels.The racks where AL and I used some 1"x3" x 1/8" extruded stock as the top cap.  We drilled 3 holes in the top to provide mounting holes to the existing ladder rack. Attached ImagesBrianLincoln Mig 215Miller 211Victor Torch SetMiller Maxstar 200SDMiller Syncrowave 250DX Tig runnerMiller Trailblazer 302 running on LPMiller Extreme 12 VS SuitcaseEllis 1600 BandsawMiller xmt350 CC/CVLincoln Vantage 300
Reply:Here are a few of the brackets as installed.  I had to make 20 total.  These pics are of a new expansion area and did not have the cat6 panels existing.  I did not get any pics of the existing area yet.  I will post them when I return to the customer site for the next phase.Thanks for looking....Have a Great Day.its time for a  Attached ImagesBrianLincoln Mig 215Miller 211Victor Torch SetMiller Maxstar 200SDMiller Syncrowave 250DX Tig runnerMiller Trailblazer 302 running on LPMiller Extreme 12 VS SuitcaseEllis 1600 BandsawMiller xmt350 CC/CVLincoln Vantage 300
Reply:Wow Brian!  I've never done that type of work before (fiber optics and cable) but it's easy to see that was some right smart thinking and great design.  Real nice fabrication work too.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Thanks.  I figured I'd post it because it was something different.Its not my best welding but considering we had a short period of time to provide a solution and resources ($$$$) I think it accomplished what we set out to do.  The customer was happy as well.  Especially because the brackets did not take long to install and they did not have to supervise us all night long....BrianLincoln Mig 215Miller 211Victor Torch SetMiller Maxstar 200SDMiller Syncrowave 250DX Tig runnerMiller Trailblazer 302 running on LPMiller Extreme 12 VS SuitcaseEllis 1600 BandsawMiller xmt350 CC/CVLincoln Vantage 300
Reply:Good clean work. Don't know how they could complain about that. "The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:Nicely done!  I would have killed for some nice heavy duty wall brackets similar to your fab. We had to settle for stamped sheet metal to connect our cable trays to the wall when doing a large room.
Reply:Beauty, way to go eh?! Nice shop. City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:That looks clean and sharp... nice job!!!Did that al channel come with the holes pre punched in it? I can think of a lot of uses for it.Thanks,Ken
Reply:Originally Posted by KGIORThat looks clean and sharp... nice job!!!Did that al channel come with the holes pre punched in it? I can think of a lot of uses for it.Thanks,Ken
Reply:Correct Sandy.We used some standard equipment racks made by Chatsworth (CPI).  They where 7ft tall 19" Telco Equipment racks. 12-24 screw size. One Rack unit or (1ru) is 1.75" or 3 holes.These where brushed AL and kind of a PITA to weld.  The brushed finish was coarse and coated with some type of clear coat.  I hit the welded areas with a wire wheel and then wiped the area with lacquer thinner but still got some contaminates that boiled out as soon as I put the heat to it.  Some of the welds had a bit of porosity so I  made another pass over the area and added some more filler.  Next time I'm on the customers site I will get some additional pictures.  I had to hit the road for a multiple site customer VoIP install so I missed the install of the 17 remaining brackets. Have a good weekend. BrianLincoln Mig 215Miller 211Victor Torch SetMiller Maxstar 200SDMiller Syncrowave 250DX Tig runnerMiller Trailblazer 302 running on LPMiller Extreme 12 VS SuitcaseEllis 1600 BandsawMiller xmt350 CC/CVLincoln Vantage 300