DIY 16 Port Keystone Patch Panel

After running Cat-6 for my home network I started looking at Keystone patch panels.  I like the keystone system because of the versatility, I could add video, audio. phone, etc., and put them all in the same patch panel.  After doing a little shopping I was surprised at how much they were!  I got the bright idea I could build one cheaper than that so I set out to.  By the time I finished I had spent around $20.  Unfortunately, by the time you figure in the labor involved, the total investment is a lot more than buying a production model,  but building it sure was a lot more fun!

Minimum/Best Tools for this project are:
Hack saw / Cut off saw
Drill / Drill press
Jig saw / Table saw
Sandpaper / Disk and Drum sander
Hammer / Brad Nailer
Screwdriver

Parts Needed:
(3) six hole keystone cover plates - $2 each
(1) 1/16"x1/2"x3/4"x3' aluminum angle - $4
(1) 14"x9"x1/4" sanded plywood - scrap I had laying around
(1) 1"x10"x12" pine board - more scrap
(2) 6-32 brass wood insert nuts - $1.50
(2) 6-32x3/8" machine screws - $1.00
(4) stick on rubber feet - $4
Keystone plugs - 15@$0.11=$1.65

Misc.:
Paint
Brads
Wood glue
PVC cement
Loctite Weld or JB Weld
Loctite Grab-It

Now we have the tools and the parts, lets get started on the face....

Step 1 Building the Face

I chose three six hole covers so I would end up with an eighteen port patch panel but you can make your patch panel any size you like.

Start by looking at the back of the cover plate to determine "Up".  You want all your covers running the same direction as it will make it easier to insert your keystone jacks when the time comes.

Next I used a band saw to cut off the ends of the covers.  This will reduce the overall size but more importantly it will give us a flat gluing surface. Cut the outside edge of the end pieces so the alum. angle just covers them.

After cutting I squared up the ends using a disk sander and miter gauge.

Next apply purple primer to the edges of the covers, apply cement and clamp together.  Use the cement sparingly, it melts plastic.  Apply the cement to one surface and press together.  When using this on pipe, you turn the pipe a 1/4 turn to set the cement.  Mimic this by sliding or twisting the pieces before clamping.

When clamping make sure to keep face flat.

The cement will set quickly but let the face dry overnight to ensure a strong bond.  Once dry, remove the clamps and inspect your work.  You will probably see purple and cement on the face.  Simply get out your sand paper and start sanding.

Comments

[DustySeven7]

You have a patch panel. When it comes to patch panels there is not really a difference in 100mbs and 1gb speeds except the cable. You need at least cat 5e to achieve gig. Cat 6 would be better.

[ContraptionMaker]

Ya I know that Dusty, thanks, that's why I said I need to build a switch!
BTW if you had read the whole structalbe, you would have known that I have cat 6 run though out the whole house.

[LifeWarrior]

This is one amazing home-brew network system and configuration, I've been in the IT field for going on 16 years and this is probably the best version of clean and discreet I've seen in year puts my rack to shame. Now I'm considering reworking mine. Very Slick.

[ContraptionMaker]

WOW! Such high praise from an IT guy. I am honored! Thanks Roder!

[LifeWarrior]

Call'em as I see'em, I actually considered building an audio patch panel for my whole house audio instead of just having the wires run into the back of the server block. This gives me a couple of idea's for that and another rackmount project. Very cool idea.