Rockler PACK RACK User manual

Assembly Instructions
Review these instructions fully prior to use for important safety information.
Always check Rockler.com to conrm 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 injury
or 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
7
7
3
4
8
4
5
36
2
1
5
6
1
2
12
13
8
14
Through holes for #8 wood
screws or machine screws
with nut (not included)
1
2
3
4
3

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.
2
6
4
5
8
7

5
Fig. 2
Fig. 4
Fig. 3
Fig. 5
44
56
56
22

6
Fig. 6
Fig. 8
Fig. 7
Fig. 9
2
6
1
2
5
1
4
3
56
4
3

7
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.
3
1
3
1
1st assembly
1st assembly
2nd assembly

8Distributed by Rockler Companies, Inc.
Medina, MN 55340
21834
Rev 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, please
contact our Technical Support Department at 1-800-260-9663
or [e-mail]
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