Assembly Instructions

Review these instructions fully prior to use for important safety information. Always check Rockler.com to confirm that you are using the most recent manual version for your product.

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This product is designed for specific applications as defined in the instructions and should not be modified and/or used for any other applications. Before using the Pack Rack® Tool Storage System, read, understand and follow all instructions and safety information provided. KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.

GENERAL SAFETY WARNINGS

> Always confirm that you are using the most recent version of the Instructions and safety warnings for your product. To find the most recent version, find the product page on Rockler.com and click on the link to the Instructions.

> For any tool used in conjunction with this product, always read, understand and follow the instructions and safety warnings in the owner’s manual for that tool. If you do not have the owner’s manual, obtain one from the tool’s manufacturer before using it with this product.

> Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tools’ owner’s manuals.

> Do not use this product until you have read and are confident you understand: • Assembly (p. 4); • Squaring the Pack Rack® (p. 7); > Do not use this product in any manner other than what is described in these instructions. Use only recommended accessories.

> Remain alert and use good judgment when using this tool. Do not use this tool if you are in any way impaired by medications, alcohol, drugs or fatigue.

> Dress appropriately and remove all jewelry, secure loose clothing and tie up long hair before using this tool.

> It is the sole responsibility of the purchaser of this product to ensure that any third party whom you allow to use this product reads and complies with all the instructions and safety precautions outlined in this manual prior to use.

> Maintain these instructions and warnings as long as you own the product. Keep this booklet in a place where it will be readily available for reference.

> The user assumes all risk and responsibility for the proper use of this product and for ensuring product suitability for intended application.

> Always wear safety glasses in compliance with ANSI safety standards and hearing protection and follow all standard shop safety practices, including: • Keep your work area well lit and clean; • Unplug all power tools before making any adjustments or changing accessories; • Use dust collection tools and dust face masks to reduce exposure to dust; • Use accessory safety equipment such as featherboards, push sticks and push blocks whenever appropriate; • Do not use power tools in explosive environments (e.g., in the presence of flammable liquids, fumes or dust); • Keep children and bystanders away from the tool operating area; • Maintain proper footing at all times and do not overreach; • Do not force the tool. > These warnings and instructions do not represent the total of all information available regarding tool safety, use and technique. Please read the full manual before using this product and always seek out opportunities to learn more and improve your skills and knowledge.

Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known ot the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go to www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injuryor property damage.

Notice indicates important or helpful information and/or user tips.

BP0617

Quantity 1 Upper Front Stretchers (233⁄8" L w/label) 2 2 Upper Side Stretchers (117⁄8" L) 2 3 Lower Front Stretchers (233⁄8" L) 2 4 Lower Side Stretchers (293⁄8" L) 2 5 Left Legs (541⁄2" L) 2 6 Right Legs (541⁄2" L) 2 7 Non-Locking Swivel Casters 2

PARTS LIST - PACK RACK Quantity 8 Locking Swivel Casters 2 9 3/4" Caster Nuts (not shown) 4 10 5/16-18 Bolts (not shown) 32 11 5/16-18 Nuts (not shown) 32 12 5/8" Clamp Rods 8 13 Retainer Pins 16 14 Shelf Hooks 4

TOOLS NEEDED• 1/2" Box Wrench • Carpenter’s Square• 1/2" Socket • Sliding T-Bevel or Angle Finder• 3/4" Box Wrench (for Caster Nut)

Stretcher Profiles

Lower Side Stretchers

Lower Front Stretchers

Upper Side Stretchers

Upper Front Stretchers

77

3

4

8

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5

36

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1

5

6

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212

13

8

14

Through holes for #8 wood screws or machine screws with nut (not included)

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Assembly

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Fig. 2

1. On the floor or a large workbench, lay out one Left Leg (5) and one Right Leg (6), as well as one 117⁄8" Upper Side Stretcher (2) and one 293⁄8" Lower Side Stretcher (4). Fig. 1. Attach one Non-Locking Swivel Caster (7) to the bottom of the Left Leg (5) and one Locking Swivel Caster (8) to the bottom of the Right Leg (6) using 3/4" Caster Nuts (9).

2. Starting with the upper left corner, fasten the Left Leg (5) and the Upper Side Stretcher (2) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11). Use the hole closest to the inside corner of the leg. Leave the adjacent hole open at this time. Fig. 2.

3. Move to the upper right side and fasten the Right Leg (6) and the Upper side Stretcher (2) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11), using the hole closest to the inside corner of the leg. Fig. 3.

4. Move to the lower left side and fasten the Left Leg (5) to the Lower Side Stretcher (4) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11), using the hole closest to the inside corner of the Left Leg (5). Fig. 4.

5. Move to the lower right side and fasten the Right Leg (6) to the Lower Side Stretcher (4) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11), using the hole closest to the inside corner of the Left Leg (5). Fig. 5.

6. Leave this side assembly on the floor or bench. Repeat steps 1-5 on the remaining legs and side stretchers.

To make assembly easier, begin by installing 1 bolt per connection. Once all pieces are connected, square the rack and finish by installing and remaining bolts and tighten securely.

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Fig. 2

Fig. 4

Fig. 3

Fig. 5

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5 6

5 6

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Fig. 6

Fig. 8

Fig. 7

Fig. 9

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43

5 6

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Fig. 10 Fig. 11

7. Starting with the upper left corner of your first side assembly, fasten the Upper Front Stretcher (1) perpendicular to the Left Leg (5) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11), using the hole closest to the inside corner of the Left Leg (5). Fig. 6.

8. Move to the upper right corner and fasten the Upper Front Stretcher (1) perpendicular to the Right Leg (6) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11), using the hole closest to the inside corner of the Right Leg (6). Fig. 7.

9. Move to the lower left corner, fasten the Lower Front Stretcher (3) perpendicular to the Left Leg (5) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11), using the hole closest to the inside corner of the Left Leg (5). Fig. 8.

10. Move to the lower right corner and fasten the Lower Front Stretcher (3) perpendicular to the Right Leg (6) with a 5/16-18 Bolt (10) and 5/16-18 Nut (11), using the hole closest to the inside corner of the Right Leg (6). Fig. 9.

11. At this point your first side assembly should look like Fig. 10.

12. Place the second side assembly over the assembly with front stretchers attached. Attach the second side assembly with 5/16-18 Bolts )10) and 5/16-18

Fig. 12

Nuts (11), using the hole closest to the inside corner of each front stretcher. Fig. 11.

Squaring the Pack Rack®

1. Bring the Pack Rack® to an upright position; lay a carpenter’s square flat on the bottom inside ledge of the rack and adjust to square. Move to the opposite corner and repeat. Fig. 12. Since there is only one bolt in all corners, the rack will be easy to adjust for flat and square.

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1

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1

1st assembly

1st assembly

2nd assembly

8 Distributed by Rockler Companies, Inc. Medina, MN 55340

21834Rev 08/17

Fig. 17

Fig. 13

Fig. 16

2. Place the carpenter’s square on the top edge of the Lower Front Stretcher (3). Move the square so its left edge is against the edge of the Left Leg (5) and adjust the assembly as needed. Fig. 13. Do the same procedure for the opposite corner.

3. Using a sliding T-bevel or adjustable angle finder, square the side of the rack. Fig. 14. The upper angle should roughly measure 100°, and the lower angle should roughly measure 80°. The important part is that the opposing angles are as close to each other as possible.

4. Once the Pack Rack® is square, go around every corner and install all of the remaining 5/16-18 Bolts (10) and 5/16-18 Nuts (11).

5. Slide the 5/8" Clamp Rods (12) into the holes along the legs (5 and 6) and secure with Retainer Clips (13). Fig. 15.

6. The Shelf Hooks (14) are attached to the underside of a shop-made shelf using #8 wood screws or a machine screw and nut for added stability. Fig. 16. The bottom of the Pack Rack® is designed to accept a shop-made shelf with cut corners to be dropped into place. Fig. 17.

Fig. 15

Fig. 14

Check Rockler.com for updates. If you have further questions, pleasecontact our Technical Support Department at 1-800-260-9663 or support@rockler.com

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