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Re: Patch-panel fabrication

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On 5/6/2017 8:15 PM, whit3rd wrote:
> On Saturday, May 6, 2017 at 3:40:13 PM UTC-7, Don Y wrote:
>> On 5/5/2017 10:33 PM, Don Kuenz wrote:
>
>>> We live in a keystone world. It's hard to believe that Greenlee doesn't
>>> offer a keystone knockout.
>>
>> The problem isn't finding a way to cut a hole in a piece of material.
>> Rather, it has to do with getting *enough* "hole" in a piece of material
>
>> Look, again, at the front view of the panel.  Imagine those were 48 individual
>> keystone connectors.  How would you arrange them on the panel as a set
>> of *48* individual connectors?  48 individually punched holes?
>
> One way would be a Keystone x6 wallplate with blank area to the right holding labels for the
> six ports, alternating downward with a blank area to the left holding labels for a
> wallplate on the right.  Eight such  wallplate=sized items would take up about
> 40 vertical inches; intersperse with mount points for some switches/routers
> and put an AC power strip on the bottom.   It'll all hide behind a 10" wide set of
> tiles or a sculpted plaster column... or a mirror..

You misunderstand; I don't have an arbitrary space to play with.
Remember, the cables from the panel have to connect *to* something!
In my case, the *switch*.

I have a space (actually, two spaces) that are the size and shape of
half of a 96 position rack mount patch panel (which is why I used
*photos* of such things as examples of the space, so you could get
an idea as to the connector density -- the amount of "hole" removed
from any fabricated panel).

Look at the problem from the top.  Let's use *your* house, for
example (as you are infinitely more familiar with its layout).

[No basement or attic allowed, though (cuz we don't have either, here).
And, garage is similarly off-limits unless you want to air-condition it
(and hope nothing crawls inside the kit or the wiring spaces made
accessible as a result of its presence).]

First, you need to find a location for a 96 port *switch*.
Silly to worry about where to terminate the patch panel if
the switch to which it tethers isn't within a convenient
span!

Of course, you'll need to have power nearby for the switch
to operate.  As the rest of the distributed kit is powered
from the switch (PoE), the switch must be capable of sourcing
all of that power -- 1400W in my case.  So, you can't just
pick any old branch circuit and HOPE it has that much
*surplus* capacity (a 15A circuit derated to 80% leaves you
with 1440W capacity).

[We'll forget about the backup power supply, for now, as it
could potentially be located elsewhere -- as long as the
branch circuit that feeds the switch is ensured to be "up"]

Then, you have to ensure the heat thrown off by the switch has
a place to go.  And, that any active cooling won't be a nuisance
to the occupants of the residence (*you* wouldn't want to be
listening to fans running 24/7/365, right?).

And, you have to make it not be obtrusive.  You don't want to
have to look at the thing and explain it to your friends,
neighbors, houseguests etc.  (tough enough having to explain
why there's a pinball machine in the front hallway).

Finally, it has to be marginally accessible; you don't
want to have to move the refrigerator to gain access to it
lurking behind!  It would be nice if you could notice
"out of the corner of your eye" that something was remiss
(e.g., why is that FAULT indicator flashing?)

Have you found that place in YOUR home, yet?  :>

Here, the floorplan is very open.  No places to stash things
besides the *few* closets, pantry, etc.  The only "utility"
rooms are the laundry and the "furnace room".  Neither has
a place for a big switch without removing some existing item
(we need the HVAC and I'm not keen on commuting to the
laundromat weekly!)

[For example, the office kit is wired to a 24 port switch
fastened to the *underside* of one of the work surfaces -- as
are all of the network cables feeding that switch!]

So, that leaves "living space".  The idea of putting a rack -- even
something just big enough for switch plus panel -- in any of the
living-, dining-, family-, kitchen-, bed- or bath -rooms ain't
gonna fly.  Even if I put a big *plant* on it and claimed it
was a modernist PLANTER ("Why does your planter make that noise?")
or, cover it with a glass top and claim its a coffee table!!

Closets/pantries don't tend to have power -- but, you could
always *add* a branch circuit without that looking too odd
(this also gets around the concern for how lightly/heavily
loaded any OTHER branch circuit might be!)

But, if you don't want to *dedicate* the closet/pantry to an
"equipment closet" (cuz we have so LITTLE/FEW "hiding places"
in the floor plan), then you have to figure out how to
share the space with the things that have already laid claim
to the space!

You'd NOT want to surrender the *choice* spots in that
storage space to this kit as it rarely needs to be
accessed -- as long as you can get to it when you
NEED to and have some way of verifying its approximate
functionality without interacting with a "system console".

So, you pick the most out-of-the-way parts of the space
and use those.  E.g., UNDER the lowermost shelf as
most folks don't like bending down that far to extract
something from storage (we typically keep things like
bulk supplies down that low -- things that we can shove
in with a foot or *drag* back out; those could easily be
moved up a shelf to free that space -- with only moderate
grumbling from SWMBO)

But, remember, you need space for the switch *and* the
patch panel.  If you stack them vertically, then you
risk eating up TWO shelves.  OTOH, if you effectively
place one in front of the other, then they consume no
more vertical height than either, individually!  (this
assumes you don't have space to put them side-by-side;
*two* rack widths)

A bit of thought makes it obvious that literally stacking
one in front of the other won't work.  But, you can
put them at right angles to each other, shifting
the bulkiest component(s) -- i.e., the switch, UPS,
etc. -- BACK a bit to make room on the side(s) for
a patch panel.  And, with TWO sides available, you
can split the panel so its height (or depth/width) can
be halved.

+-------PPPPP-
|
| SSSS
| SSSS
| SSSS
| SSSS
| SSSS
|
+-------PPPPP-

This has the added benefit of allowing the wires to
connect to the rear of the panel through the natural
cavity in the wall (taking precautions with firestops
and fire-retardent caulk on the penetrations thereof).

This keeps all the patch cords in one dense area
instead of spread out vertically or horizontally
(or both).  So, all connections to the panel(s)
are accessible.  And, lets the entire front of the
switch remain accessible (if the space is a bit wider
than the switch itself to allow the cables to dress
to the left and right of it)

> The 48-position rackmount item is not as easy to hide or decorate.
> Using the parts from that rackmount is only easy if you rivet some studs into
> the metal of your faceplate to act as circuitboard  mountpoints (and have
> a convenient way to get to the back to affix the wires).

The back is accessed by removing the panel from its
attachment to the wall -- just like it would be
accessed in a rack (you wouldn't try to reach THROUGH
a rack to access the rear-side of the individual
connectors).

The little circuit boards mount to the panel face in the same way
that they do to a COTS metal face:  with long screws through
unthreaded standoffs (spacers).  In effect, "studs".

For a front panel that has been reinforced by adding a stiffening
layer behind the visible face, the screw heads can protrude through
the back reinforcing layer, countersunk.  The visible front layer
can be adhered to the reinforcing layer rendering the screw
heads invisible (and inaccessible).  To keep a screw captive, a
nut threaded onto each screw on the rear surface of the reinforcing
panel ensures that the screw never loosens -- much like a stud is
never expected to loosen from a panel from which it has been
"extruded".  (remember, there's space behind the panel before you
reach the circuit boards)

I.e., layout front panel so it is cosmetically arranged as you'd like.
Trim ~3/8" from all edges of that panel and shoot another copy of
the same hole pattern -- with the holes for the "studs" added.  Insert
screws ("studs") into this smaller reinforcing panel and fasten with
nuts.  Align front panel to rear panel (using cutouts for connectors)
and adhere.  Thread standoffs -- shortened by the thickness of the
reinforcing panel -- onto the captive screws.  Follow with the
PCB's and a final locknut to hold captive.

No visible hardware on the front panel.  Wiring side remains
accessible (by removing panel from wall mount).  Defective
connectors (inevitable, over time) replaced by removing the
afflicted PCB and replacing with repaired unit -- snipping
the "used" portion of the 4/6/8/12 network cables off each
and reconnecting to the punchdown blocks.

Panel can now be a piece of tacky techy sheet metal, acrylic,
hardwood, etc.  Reinforcement layer can differ in composition
from the visible layer.

Sell home?  Remove custom switch and 1U slide-out console.  Replace
with a smaller, more vanilla, "green" switch.  Pitch it as a
*feature* to prospective homeowners:
    "The house is completely wired and here's a convenient,
     out-of-the-way place for you to locate your network printer,
     ISP modem, wireless router, media tank, etc. -- and, without
     significantly impacting the generic storage space available!
     You could even get in the habit of placing your portable
     devices on a shelf in here to be recharged -- there's an
     electric outlet right over there for their wall wart chargers!"

[I'm hoping to finagle another shelf, there, and move one of
the low volume printers and a few other small bits of kit
(like some of the NAS's) into there, as well, to get them out
of the office]

Repeat the exercise for the other "systems" in the house
and you quickly discover there's more effort involved
trying to terminate wires and *hide* things than you could
ever imagine!  :-/

I had hoped to fab a sample panel, tonight.  But, ran late and
had to defer to other obligations.  *But*, my buddy offered
to cut it for me (without me having to hang around):  "Let
me see what *I* can do..."  Hopefully, I'll get back over there
tomorrow to pick it up and run some "empirical tests".

(I imagine there are ways to *design* things with suitable
mechanical and anthropomorphic characteristics but I have
to rely on instinct and physical mock-ups:  cables are too
close together; panel flexes too much; etc.)

[I'd genuinely be interested in how you'd accommodate something like
this in your existing home as I'll be needing ideas to suggest to
others who want to travel the same road -- WITHOUT having to
"build a custom home"!]

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Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-03 12:54 -0700
  Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-03 13:23 -0700
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 00:10 -0700
      Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-04 11:27 -0700
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:43 -0700
        Re: Patch-panel fabrication Clifford Heath <no.spam@please.net> - 2017-05-05 08:57 +1000
          Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-06 05:47 -0700
        Re: Patch-panel fabrication krw@notreal.com - 2017-05-04 19:37 -0400
      Re: Patch-panel fabrication Neon John <no@never.com> - 2017-05-04 17:56 -0400
        Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-06 05:46 -0700
      Re: Patch-panel fabrication Jasen Betts <jasen@xnet.co.nz> - 2017-05-11 05:57 +0000
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-11 10:37 -0700
  Re: Patch-panel fabrication Martin Riddle <martin_ridd@verizon.net> - 2017-05-03 20:32 -0400
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-03 23:59 -0700
  Re: Patch-panel fabrication Jasen Betts <jasen@xnet.co.nz> - 2017-05-04 06:34 +0000
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 01:45 -0700
  Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-04 01:52 -0700
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:42 -0700
      Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-04 21:22 -0700
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 23:04 -0700
          Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-04 23:24 -0700
            Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-05 00:19 -0700
              Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-05 00:45 -0700
                Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-05 02:17 -0700
  Re: Patch-panel fabrication jrwalliker@gmail.com - 2017-05-04 08:40 -0700
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 10:12 -0700
      Re: Patch-panel fabrication jrwalliker@gmail.com - 2017-05-04 10:27 -0700
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:01 -0700
          Re: Patch-panel fabrication makolber@yahoo.com - 2017-05-04 11:18 -0700
            Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:27 -0700
      Re: Patch-panel fabrication Don Kuenz <g@crcomp.net> - 2017-05-06 05:33 +0000
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-06 15:40 -0700
          Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-06 20:15 -0700
            Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-06 23:47 -0700
              Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-07 03:51 -0700
                Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-07 05:20 -0700
          Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 17:30 +0000
            Re: Patch-panel fabrication (POE) Don Y <blockedofcourse@foo.invalid> - 2017-05-07 11:49 -0700
              Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 18:58 +0000
                Re: Patch-panel fabrication (POE) Don Y <blockedofcourse@foo.invalid> - 2017-05-07 12:24 -0700
                Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 19:48 +0000
                Re: Patch-panel fabrication (POE) Don Y <blockedofcourse@foo.invalid> - 2017-05-07 13:29 -0700
                Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 20:54 +0000
  Re: Patch-panel fabrication Allan Herriman <allanherriman@hotmail.com> - 2017-05-07 10:35 +0000
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-07 05:26 -0700

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