Design package · rev D · column racks · 2 orientations

4000D Column Rack

Single-width columns of pull-out trays, sized to your 2200 mm limit, in two orientations: upright (3/column → 6 columns) or horizontal, servers on their side (6/column → 3 columns). Real fan set, open rear, optional closed sides, phenolic-ply shelves, tGBL castors — with an exploded view and step-by-step assembly in the configurator.

upright 3/col · 6 colshorizontal 6/col · 3 colsP14×3 front / P12×3 top / P14 rearopen rearoptional sidesAOLISHENG 600 mm slidestGBL 100 mm castors

01 · two orientations

Upright or horizontal

Upright stacks 3 (taller, narrower); horizontal lays each tower on its side for 6/column (shorter per level, wider, steadier). Pick per row.

02 · sliding trays

Pull one server out

Every level on AOLISHENG 600 mm soft-close slides (45 kg). Draw one out fully for service.

03 · fans

P14 ×3 / P12 ×3 / P14

Arctic P14 ×3 front intake, P12 ×3 top exhaust, 1× P14 rear — front-to-back-and-up airflow, animated in the browser.

04 · open rear

Rear stays open

No closed plenum. The rear P14 exhausts to open air; the PiKVM + cabling live in the open rear space.

05 · optional sides

Controlled circulation

Add side panels to duct the flow front-to-rear, or leave them off for maximum open airflow. Toggle in the model.

06 · exploded + assembly

Break apart & build

An exploded-view slider and a numbered assembly guide with sizes — see the configurator's Assembly tab.

Upright vs horizontal — every material

All fit the 2200 mm limit. Horizontal is wider but shorter per level, so it doubles servers-per-column and is less slender (steadier).

Material	Orient	N/col	W×H×D mm	Col kg	Cols	Per col	Fleet	Slender
Aluminium	Upright	3	348×1847×718	93.5	6	£428	£2568	5.2
Aluminium	Horizontal	6	584×2138×718	170.6	3	£703	£2109	3.6
Welded	Upright	3	328×1807×698	96.4	6	£364	£2184	5.4
Welded	Horizontal	6	564×2068×698	175.3	3	£587	£1761	3.6
Dimensional	Upright	3	344×1839×766	83.4	6	£281	£1686	5.2
Dimensional	Horizontal	6	580×2124×766	155.2	3	£461	£1383	3.6

Fans & airflow

🔵 Front intake — Arctic P14 ×3

🔴 Top exhaust — Arctic P12 ×3

🔴 Rear exhaust — 1× Arctic P14

Cool air is pulled in the filtered front, over the boards, and pushed out the top and the open rear. The rear is deliberately left open so the P14 exhausts freely and the PiKVM sits in that space. Toggle Airflow in the configurator for an animated particle flow (it runs on your GPU in the browser). A quantitative CFD pass on the RTX 5090 is possible if you want pressure/temperature numbers.

Assembly — step by step

Break the model apart with the exploded slider, then follow the steps. Sizes below are Aluminium · upright; the configurator shows them for the selected material and orientation.

1
Cut the frame · uprights 1747 mm
Cut 4 uprights @ 1747 mm, 4 width rails @ 268 mm, 4 depth rails @ 638 mm, and 6 shelf width rails @ 268 mm + 6 slide rails.
2
Mark the hole ladder · 64 mm pitch
On all 4 uprights, mark/drill the 64 mm adjustment hole ladder from 30 mm up. Shelves later fix to any pair — this is what makes shelf height adjustable.
3
Build the base · 268×638 mm
Join the 2 front/rear width rails and 2 side depth rails into the base rectangle (268×638 mm) with corner brackets + M8 T-nuts. Check the diagonals are equal before locking.
4
Stand the uprights · H 1847 mm
Fix the 4 uprights to the base corners; add the top rectangle the same way. Square the column (diagonals equal) and lock every joint.
5
Fit the shelf rails · pitch 569 mm × 3
At each level (pitch 569 mm), bolt/screw the front, rear and 2 side shelf rails to the chosen hole pair. Repeat for all 3 levels.
6
Mount the slides · 600 mm slides × 3
Screw an AOLISHENG 600 mm slide pair to the two side rails at each level, flush to the front. Soft-close end to the rear.
7
Cut & fit the trays · 18 mm phenolic ply
Cut 3 × 18 mm phenolic-ply trays (perimeter frame, centre open for the PSU intake), pre-drill, and screw to the slide inner members.
8
Castors + anti-tip · tGBL 100 mm ×4
Bolt the 4 tGBL 100 mm castors (2 braked) to the base with the supplied bolts/nuts, and fit the front anti-tip feet.
9
Rear kit · 175 mm rear
Mount each PiKVM in the open rear space and route HDMI/USB/ATX with a service loop so the tray can slide. Leave the rear OPEN for the P14 exhaust.
10
Mesh door (+ optional sides) · 718 mm deep
Hang/clip the mesh pre-filter door on the front. Optionally add the side panels for controlled circulation.
11
Load servers · 3 servers
Slide each 4000D onto its tray (standing upright), heaviest (VDI) at the bottom. Confirm the fans: P14 ×3 front intake, P12 ×3 top exhaust, P14 rear exhaust.

Clearances

Clearance	Value	Why
Case side → upright (each side)	19 mm	slide 13 + gap 6; door mesh clears the front
Top exhaust gap (case → shelf above)	45 mm	P12 ×3 exhaust vents up into the open gap
Open rear space (case back → frame)	175 mm	rear P14 exhaust + PiKVM + cabling — REAR STAYS OPEN
Tray pull-out travel	600 mm	clears the 453 mm case by 147 mm
Front clearance needed (aisle)	600 mm	keep clear in front of every column
Floor → first tray	140 mm	tGBL 100 + base shelf
Level pitch (server to server)	569 mm	tower standing
Rear airflow clearance	≥ 150 mm	keep the rear open so the P14 can exhaust freely

Materials, castors & fasteners

shelves

18 mm phenolic ply

Black, waterproof, structural — 0.055 mm deflection under a loaded tray. Pre-drill + countersink.

castors

tGBL 100 mm, 150 kg ea.

Bolt-on, 2 braked, rubbered/silent, no floor marks. 600 kg/set — huge margin over a ~93 kg column.

adjustable

64 mm hole ladder

Move the shelf rail to a new hole pair to change height — Torx screws / T-nuts, no re-cutting.

Fastener schedule

Dimensional

Joint	Fastener	Note
Rails → uprights	5.0 × 70 mm Torx (T25) wood screw, 2/end + PVA	structural; 3 mm pilot
Phenolic-ply tray/shelf	5.0 × 60 mm Torx (T25), pre-drill + countersink	phenolic ply must be pre-drilled
Slides → uprights	4.0 × 40 mm Torx (T20) wood screw	every slide hole
Shelf adjust	back out the 5.0 mm Torx, move rail to next 64 mm hole	hole ladder pre-drilled
Castors → base	M8/M10 coach bolt + nut (supplied with tGBL)	through the 2×3 base

Aluminium

Joint	Fastener	Note
Frame joints	M8 button-head + drop-in T-nut	2 per corner bracket
Slides → uprights	M5×10 button-head + T-nut	AOLISHENG holes into the T-slot
Shelf adjust	loosen 4× M8, slide bracket, retighten	stepless along the slot
Castors → base	M10 bolt + nyloc (supplied with tGBL)	through the base rail

Mesh pre-filter door — options

Magnetic snap-on filter (recommended)≈£6/level

Demciflex-style: a laser-cut 2 mm aluminium/ABS frame holding washable ~150 µm PET mesh, magnet-held to steel washers around the front. Tool-less, lift off, rinse. ~0.3 kg/level, lowest pressure drop.

Hinged perforated-aluminium door≈£28/door

1 mm perforated/expanded aluminium in a light frame, piano-hinged with a magnetic catch, full height, replaceable media behind. Sturdiest. ~0.9 kg.

Nylon mesh in a printed frame≈£3/level

Washable nylon range-hood mesh in a PETG-printed frame, twist-lock or magnet mount. Cheapest, reprintable. ~0.25 kg/level.

Two-layer coarse+fine+£4/level

Coarse aluminium mesh in front of fine electrostatic media for dusty rooms — keep >50% open area so the P14s aren't choked.

Every variant

Aluminium T-slot extrusion · Upright (towers standing)

£428/col · £2568/fleet

Envelope & loads

W×H×D	348 × 1847 × 718 mm
Servers/col	3
Pitch	569 mm
Columns for 16	6 (18)
Loaded	93.5 kg
Tip SF (anti-tip)	5.99
Slenderness	5.2
Floor	374 kg/m²

BOM (per column)

Item	Qty	Unit	£
4040 T-slot profile (8 mm slot), 6063-T5	7	x 3 m	£160
AOLISHENG 600 mm full-ext soft-close slides, 45 kg/pair	3	pairs	£144
18 mm phenolic-ply tray/shelf (black, waterproof)	3	trays	£21
Mesh pre-filter door (alu mesh + light frame + magnets)	1	door	£28
Arctic P14 (front×3 + rear×1) + P12 (top×3)	3	sets/level	£0
Corner brackets + M8 T-nuts/bolts	20	sets	£21
tGBL 100 mm bolt-on castor, 150 kg each, 2 braked (silver, rubbered)	1	pack of 4	£32
Optional: side panels (controlled circulation)	2	panels	£14
Anti-tip feet + EPDM/gaskets	1	set	£8

Aluminium T-slot extrusion · Horizontal (towers on their side)

£703/col · £2109/fleet

Envelope & loads

W×H×D	584 × 2138 × 718 mm
Servers/col	6
Pitch	333 mm
Columns for 16	3 (18)
Loaded	170.6 kg
Tip SF (anti-tip)	10.92
Slenderness	3.6
Floor	407 kg/m²

BOM (per column)

Item	Qty	Unit	£
4040 T-slot profile (8 mm slot), 6063-T5	11	x 3 m	£258
AOLISHENG 600 mm full-ext soft-close slides, 45 kg/pair	6	pairs	£288
18 mm phenolic-ply tray/shelf (black, waterproof)	6	trays	£42
Mesh pre-filter door (alu mesh + light frame + magnets)	1	door	£28
Arctic P14 (front×3 + rear×1) + P12 (top×3)	6	sets/level	£0
Corner brackets + M8 T-nuts/bolts	32	sets	£33
tGBL 100 mm bolt-on castor, 150 kg each, 2 braked (silver, rubbered)	1	pack of 4	£32
Optional: side panels (controlled circulation)	2	panels	£14
Anti-tip feet + EPDM/gaskets	1	set	£8

Welded steel square tube · Upright (towers standing)

£364/col · £2184/fleet

Envelope & loads

W×H×D	328 × 1807 × 698 mm
Servers/col	3
Pitch	559 mm
Columns for 16	6 (18)
Loaded	96.4 kg
Tip SF (anti-tip)	6.07
Slenderness	5.4
Floor	421 kg/m²

BOM (per column)

Item	Qty	Unit	£
30x30x2 mm mild steel square hollow section	4	x 6 m	£95
AOLISHENG 600 mm full-ext soft-close slides, 45 kg/pair	3	pairs	£144
18 mm phenolic-ply tray/shelf (black, waterproof)	3	trays	£21
Mesh pre-filter door (alu mesh + light frame + magnets)	1	door	£28
Arctic P14 (front×3 + rear×1) + P12 (top×3)	3	sets/level	£0
Weld consumables + primer/paint	1	lot	£22
tGBL 100 mm bolt-on castor, 150 kg each, 2 braked (silver, rubbered)	1	pack of 4	£32
Optional: side panels (controlled circulation)	2	panels	£14
Anti-tip feet + EPDM/gaskets	1	set	£8

Welded steel square tube · Horizontal (towers on their side)

£587/col · £1761/fleet

Envelope & loads

W×H×D	564 × 2068 × 698 mm
Servers/col	6
Pitch	323 mm
Columns for 16	3 (18)
Loaded	175.3 kg
Tip SF (anti-tip)	11.01
Slenderness	3.6
Floor	445 kg/m²

BOM (per column)

Item	Qty	Unit	£
30x30x2 mm mild steel square hollow section	6	x 6 m	£153
AOLISHENG 600 mm full-ext soft-close slides, 45 kg/pair	6	pairs	£288
18 mm phenolic-ply tray/shelf (black, waterproof)	6	trays	£42
Mesh pre-filter door (alu mesh + light frame + magnets)	1	door	£28
Arctic P14 (front×3 + rear×1) + P12 (top×3)	6	sets/level	£0
Weld consumables + primer/paint	1	lot	£22
tGBL 100 mm bolt-on castor, 150 kg each, 2 braked (silver, rubbered)	1	pack of 4	£32
Optional: side panels (controlled circulation)	2	panels	£14
Anti-tip feet + EPDM/gaskets	1	set	£8

Dimensional lumber (2x3) · Upright (towers standing)

£281/col · £1686/fleet

Envelope & loads

W×H×D	344 × 1839 × 766 mm
Servers/col	3
Pitch	567 mm
Columns for 16	6 (18)
Loaded	83.4 kg
Tip SF (anti-tip)	5.59
Slenderness	5.2
Floor	317 kg/m²

BOM (per column)

Item	Qty	Unit	£
2x3 SPF (38x64 mm actual); 18 mm phenolic-ply shelves	8	x 2.44 m	£23
AOLISHENG 600 mm full-ext soft-close slides, 45 kg/pair	3	pairs	£144
18 mm phenolic-ply tray/shelf (black, waterproof)	3	trays	£21
Mesh pre-filter door (alu mesh + light frame + magnets)	1	door	£28
Arctic P14 (front×3 + rear×1) + P12 (top×3)	3	sets/level	£0
Torx wood screws — 5.0×70 (T25) rails, 5.0×60 ply, 4.0×40 slides	1	box	£11
tGBL 100 mm bolt-on castor, 150 kg each, 2 braked (silver, rubbered)	1	pack of 4	£32
Optional: side panels (controlled circulation)	2	panels	£14
Anti-tip feet + EPDM/gaskets	1	set	£8

Dimensional lumber (2x3) · Horizontal (towers on their side)

£461/col · £1383/fleet

Envelope & loads

W×H×D	580 × 2124 × 766 mm
Servers/col	6
Pitch	331 mm
Columns for 16	3 (18)
Loaded	155.2 kg
Tip SF (anti-tip)	10.37
Slenderness	3.6
Floor	349 kg/m²

BOM (per column)

Item	Qty	Unit	£
2x3 SPF (38x64 mm actual); 18 mm phenolic-ply shelves	13	x 2.44 m	£38
AOLISHENG 600 mm full-ext soft-close slides, 45 kg/pair	6	pairs	£288
18 mm phenolic-ply tray/shelf (black, waterproof)	6	trays	£42
Mesh pre-filter door (alu mesh + light frame + magnets)	1	door	£28
Arctic P14 (front×3 + rear×1) + P12 (top×3)	6	sets/level	£0
Torx wood screws — 5.0×70 (T25) rails, 5.0×60 ply, 4.0×40 slides	1	box	£11
tGBL 100 mm bolt-on castor, 150 kg each, 2 braked (silver, rubbered)	1	pack of 4	£32
Optional: side panels (controlled circulation)	2	panels	£14
Anti-tip feet + EPDM/gaskets	1	set	£8

Assumptions

Corsair 4000D 453 D × 230 W × 466 H mm, 7.8 kg. Verify foot spacing lands on the tray side bars.
Roles bottom-heavy; every level designed to the VDI (20 kg) worst case.
Rear left open for the P14 exhaust; sides optional for controlled flow.
Floor-anchor or gang columns; keep the anti-tip feet. Costs in £, materials only, ±40%.