Rockler Pack Rack BDL7878 User manual

Review full instructions prior to use for important safety information.
Always check Rockler.com to confirm that you are using the most recent version of instructions for your product.
Pack Rack®Instructions
Effective April 2020

2BP1219
GENERAL SAFETY WARNINGS
This product is designed only for specific applications as defined in the instructions and should not be modified or used for
any manner not described in these instructions. Use only recommended accessories. Before using the Pack Rack®: READ,
UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS
READILY AVAILABLE FOR FUTURE REFERENCE.
>Always confirm that you are using the most recent version of
the Instructions and safety warnings for your product (see the
Instructions link on the product page at Rockler.com).
>Before using another tool 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 any chemical with this product, always read,
understand and follow all safety warnings and guidelines in
the manufacturer’s Safety Data Sheet (SDS; formerly called
“MSDS”), especially regarding:
• How to safely use the chemical, including potential hazards
and recommended first aid measures;
• Personal safety equipment required to safely use the
chemical (e.g. gloves, eye protection, mask/respirator, etc.);
• Proper and safe handling, storage and disposal of
the chemical.
>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 tool’s owner’s manual.
>Do not use this product until you have read and are
confident you understand:
• Parts List (p. 3);
• Tools Needed (p. 3);
• Assembly (pp. 4 - 7);
• Squaring the Pack Rack®(p. 8).
>The user assumes all risk and responsibility for the proper and
safe use of this product and for ensuring product suitability for
the intended application.
>It is the sole responsibility of the purchaser of this product to
ensure that any anyone you allow to use this product reads
and complies with all instructions and safety precautions
outlined in this manual prior to use.
>Follow all standard shop safety practices, including:
• Keep children and bystanders away from the tool
operating area;
• Do NOT use power tools in explosive environments, or in
the presence of flammable liquids, fumes or dust;
• TURN OFF AND UNPLUG all power tools BEFORE
making any adjustments or changing accessories;
• Remain alert and use good judgment. Do not use this
product if you are in any way impaired by medications,
alcohol, drugs or fatigue;
• Keep your work area well lit and clean;
• Dress appropriately. Secure loose clothing, remove all
jewelry and tie up long hair before using this product;
• ALWAYS wear safety glasses, hearing protection
and respiratory protection that complies with
NIOSH/OSHA/ANSI safety standards;
• Use dust collection tools and dust face masks to
reduce exposure to dust;
• Use safety equipment such as featherboards, push
sticks and push blocks, etc., when appropriate;
• Maintain proper footing at all times and do not overreach;
• Do NOT force woodworking tools.
>These warnings and instructions do NOT represent the total
of all information available regarding tool safety, use and
technique. 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
to 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 injury
or property damage.
Notice indicates important or helpful information and/or user tips.

3
Quantity
1 Upper Front Stretcher (233⁄8" L w/label) 2
2Upper Side Stretcher (117⁄8" L) 2
3Lower Front Stretcher (233⁄8" L) 2
4Lower Side Stretcher (293⁄8" L) 2
5Left Leg (541⁄2" L) 2
6Right Leg (541⁄2" L) 2
7Non-Locking Swivel Caster 2
• 1/2" Box Wrench • Carpenter’s Square • 1/2" Socket
• 3/4" Box Wrench (for Caster Nut) • Sliding T-Bevel or Angle Finder
PARTS LIST
TOOLS NEEDED
Quantity
8Locking Swivel Caster 2
93/4" Caster Nut (not shown) 4
10 5/16"-18 Bolt (not shown) 32
11 5/16"-18 Nut (not shown) 32
12 5/8" Clamp Rod 8
13 Retainer Pin 16
Lower Side Stretchers ProfileLower Front Stretchers ProfileUpper Side Stretchers ProfileUpper Front Stretcher Profile
12 3 4
8
7
3
6
4
5
2
1
1
2
3
6
5
4
8
7
13
12
12
12
12
13
13
13

4
Assembly and Setup
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). Make sure the Upper Side Stretcher
is on the inside face of the leg, and use the hole closest to
the inside corner of the leg. Leave the adjacent hole open
for now. 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 leg. 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 leg. Fig. 5.
To make assembly easier, begin by
installing one 5/16"-18 Bolt (10) and 5/16"-18 Nut (11) per
connection. Once all pieces are connected, square the rack
and finish by installing and securely tightening the remaining
bolts and nuts.
During assembly, make sure to position all stretchers inside
the legs.
>Do NOT attempt to lift more than you are able. Obtain
the assistance of another adult if necessary.
Fig. 1
65
2
4
8
7

5
Fig. 2 - Upper Assembly
Fig. 4 - Bottom Left Corner Fig. 5 - Bottom Right Corner
2
5 6
4
7
5
4
8
6

6
Fig. 6 - Upper Left Corner Fig. 7 - Upper Right Corner
Fig. 9 - Bottom Right CornerFig. 8 - Bottom Left Corner
1 1
2 2
56
4 4
5 5
33
7 8

7
6. Leave this side assembly on the floor or bench. Repeat steps
1-5 on the remaining legs and side stretchers.
7. Starting with the upper left corner of your first side assembly,
fasten one 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 leg. Fig. 6.
8. Move to the upper right corner and fasten the other 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 leg. Fig. 7.
9. Move to the lower left corner and fasten one 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 leg. Fig. 8.
10. Switch to the lower right corner and fasten the other 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 leg. Fig. 9.
11. At this point, your first side assembly should look like
Fig. 10.
12. Lift the second side assembly onto the assembly with front
stretchers attached. Make sure the stretchers are on the
inside faces of the legs and attach the second side assembly
with 5/16"-18 Bolts (10) and 5/16"-18 Nuts (11), using the
hole closest to the inside corner of each front stretcher.
Fig. 10.
Fig. 10
Do NOT attempt to lift more than you are
able. Obtain the assistance of another adult if necessary.
If you purchased the optional Metal
Bottom Shelf (58463, sold separately), install it at this point,
before attaching the second side assembly. Just slide it
against the Lower Front and Side Stretchers (3 and 4),
under the 5/16"-18 Bolts (10) and 5/16"-18 Nuts (11)
holding the Stretchers together.
2nd Assembly
1st Assembly
3
3
1
1

8Distributed by Rockler Companies, Inc.
4365 Willow Dr. Medina, MN 55340
53871
Rev 04/20
1-800-279-4441
www.rockler.com
Check Rockler.com for updates. If you have further questions, please
contact our Technical Support Department at 1-800-260-9663
or [e-mail]
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. 11.
Because there is only one bolt in all corners, the rack will
be easy to adjust for flat and square.
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. 12. 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. 13. The upper angle should roughly
measure 100°, and the lower angle should roughly measure
80°. The important thing is that the opposing angles are
as close to each other as possible.
4. Once the Pack Rack®is square, go around to every corner
and install all of the remaining 5/16"-18 Bolts (10) and
5/16"-18 Nuts (11), taking care not to shift the
stretchers or legs.
5. Slide the 5/8" Clamp Rods (12) into the holes along the
legs (5 and 6) and secure with Retainer Clips (13). Fig. 14.
Fig. 12
Fig. 13
Fig. 11
Fig. 14
13
12