Fortigate 90G Dual Rack Mount for 19in Rack

Designing and printing this took a lot of trial and error because supporting dual Fortigate 90Gs in a 19in rack is difficult due to the weight.  The units themselves do not weigh a lot, however the objects need to have enough infill to support the weight over time.  Technically each left and right mount can support the full weight of a single Fortigate without the other side but not recommended long term.

• The RightMount is slightly longer than the LeftMount which is intentional to provide a little more wall width for the Nylon Lock Nuts.  Combined they clear a standard 19in rack width by fractions of a mm.
• The DualPowerSupplyPlatformHolder has an 80mm slot in the middle so a power supply can fit on each side.
• I am aware RackMount.IT has recently released a Dual Fortigate 90G rack mount all metal unit, however I was in the process of making this for weeks before and determined to finish it.  One of the benefits of using the 3D Printed version is it weighs ⅓ of the metal version (being plastic) and is shorter depth overall.
• The top window overhang is not ideal as it partially obstructs the top port numbering, however this is required to provide enough rigidness. 
• The Fortigate units slide into the brackets and provide a nice snug fit.  To remove simply push back on the front face plate until the Fortigate hits the back of the power supply platform holder and gently left up and out.  There is enough clearance back and forth to angle the Fortigate sightly to lift out
  • Second option is to remove the power supply platform holders so the Fortigate can be pulled straight back out

Hardware required

M3 Screws/Nuts: https://www.amazon.com/dp/B0CLM8C7M9?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_3&th=1

• (4) M3x8mm Screws
• (4) M3x6mm Screws
• (4) M3 Nuts

M3 Nylon Lock Nuts: https://www.amazon.com/dp/B0CHVTYLWC?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_1&th=1

• (4) M3 Nylon Lock Nuts

M4 Screws: https://www.amazon.com/dp/B0CHVTYLWC?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_1&th=1

• (2) M4x6mm Screws

Loctite Threadlocker Blue: https://www.amazon.com/dp/B009I2UC3Q?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_1

Assembly

• First and foremost the rubber feet that come on the bottom of the Fortigate units must be removed.  RackMount.IT's all metal adapter version has the same requirement.  Due to the forward port design it is not possible to provide enough sturdiness in the bracket to keep the rubber feet on.
• The (4) M3 Nylon Lock nuts insert into the hexagon inserts on the side the inner right mount.  The hexagon shaped holes are recessed 4.20mm inward to allow full clearance of the Fortigate unit without scraping the sides so ensure the Nylon Lock Nuts are pushed fully into the holes.
• The (4) M3x8mm screws insert into the side of left mount and should screw in all the way to be flush with the end of Nylon Lock nut (do not overtighten) on the right mount.  The M3 countersink diameter is recessed enough to allow full clearance of the Fortigate unit without scraping the sides
• The M4x6mm screws insert into the side of the outer wall into the Fortigate unit.  This is to hold the unit in place for more rigidity.  Use Locktite Threadlocker blue to provide vibration resistance
• The M3 Nuts insert into the bottom of the bracket (2) per bracket and are recessed enough to be slightly below the surface of the adapter (see pictures)
• The M3x6mm Screws insert into the top of the PowerSupplyPlatformHolder arms and all the way through to the M3 Nuts in the bottom.  The M3x6mm should sit flush with the end of the M3 nuts.  Use Locktite Threadlocker blue to provide vibration resistance
• To hold down the Power Supplies use long twist/cable ties (see pictures) or zip ties.  If using zip ties be careful not to exert too much force or the arms that hold the Power Supply Platform Holder to the main bracket can bend or break.

Printing details

• PETG or ASA (I printed PETG).  PLA is not sturdy enough for this application
• Minimum 50% Grid infill for all parts
• Increase perimeters to (4) from the default (2)
• Structure .20mm profile (not Speed)
• Print the RightMount and LeftMount standing up face down (see pictures)
• Print the PowerSupplyPlatformHolders face down so the outer curves are face up (see pictures)
  • The outer curves are designed to provide a tighter wrap around for the cable ties/zip ties.
• PETG is known for warping easier than PLA so please see below additional printing tips, however using the satin powder coated sheet should avoid needing a releasing agent on the standard smooth (Textured sheet is another great option as well).
• Potential filament modifications for better adhesion (if necessary)
  • Increase first layer bed temperature to 95C
  • Increase first layer nozzle temperature to 260C
• No supports are required, however when printing the LeftMount and RightMount a partial draft shield can be used by adding a skirt with: 2 loops, 1mm from object and 30-35 layers to provide better bed adhesion.

I printed these with the MK4 + MMU3.  

FreeCAD file is attached for desired future modifications.  All measurements are fully parametric with the accompanying spreadsheet.  Due note, the BaseMount is used as a BaseFeature for the LeftMount and RightMount.  Similarly the BasePowerSupplyPlatformHolder is a BaseFeature for the Single and Dual versions.  The BasePowerSupplyPlatformHolder also relies on a ShapeBinder against the BaseMount.

Questions/Suggestions are welcome. 

I took the original author's model idea from scratch and heavily modified it to support dual Fortigate 90Gs.  Please read the full details and instructions in the description.