10" rack spring-loaded 1U security bezel

A 10-inch spring loaded 1U security bezel.

Adds a clean front to your rack, hides messy gear but still allows easy access, prevents accidental power-button presses, and tones down those ridiculously bright OLED modules installed … or maybe that's just a problem I created for myself 😅
 

I recommend PETG for long term durability, but I prototyped in PLA and they worked just fine also.

Features

• Spring loaded latch
• Swappable grills to change the look and the clearance behind the grill
• Grill options:
  • 3x “Slim” (5.6mm rear clearance - ideal for flush mounted gear)
    • Infill (my personal pick, can be adjusted in slicer)
    • Honeycomb 
    • Solid - completely hide what's behind
  • 1x “Deep” (12.7mm rear clearance - great for protruding gear or if you have a low profile USB dongle connected)
• Want the latch on the left instead of the right, no problem.  This design works for both sides.
• No glue/screws needed.  But you will need a compression spring!

Hardware required

• 1x compression spring (I liberated mine from a standard clicky pen)
  
  It should be about 18–20 mm in length (uncompressed), ~4.25 mm outer diameter, ~3.75 mm inner diameter. 
  
  There’s wiggle room, so anything close should work fine 👍

What/how to print?

A slightly weird heading I know, but there are a few optional parts depending on your setup.

• If you’re using the Modular 10 rack like I am, print the final plate “ears_covers_for_mod10_rack_braces”.  it includes adjusted spacing in the ear covers and spacers for rack's front connector braces that are there for rigidity.
• Slim grill options are on plates starting with “bezel_grill_slim_”.  
• The deep grill is the last plate after those.  
• You do not need to print all of them, just the one(s) you want to use
• The grill plates that end in “infill” uses slicer generated latices.  A modifier on these plates is set to 50% grid pattern by default - feel free to change the pattern or density if you have another preference 😄

How to assemble

Print the parts

• "bolt_and_ears" plate
• “bezel_body” plate
• Your choice of bezel grill from one of the 4 plates

Install the ears

1. Screw the printed ears over your existing rack ears (they sit on top)
   
   The ear with the larger cut out is the latch side - install on the right or left depending on which side you prefer the latch to be.  
    

   

2. Pop the ear covers
    

   
    

Bezel assembly

1. You should have a spring and 5 printed parts waiting to go
    

   
    

2. Break the bolt in (for ~30 seconds)
   
   Insert the bolt into the housing without the spring and check it slides smoothly.

   
   If it feels tight, there's probably minor support residue, stringing, or minor surface blobs. Slide it back and forth for ~30 seconds and it should loosen up fairly quickly.
    

   
    

3. Remove the bolt from the housing again once the movement is smooth
    
4. Slide the bolt into the bezel (slightly fiddly, but it should fit - you may need to angle it slightly).
   
   It should sit flush against the side wall and pass through the side opening.
   
   Insert the spring into the back of the bolt.  It should look like the photo below
   
   
    
5. Slide the housing next and the spring should snap into place on the housing post 
   
   
    

6. Push the housing fully forward and then add in the “C” retention clip in behind it
    

   
    

7. You can now snap in the grill of your choice.  
   
   There are some small “nubs” on the bezel which help hold the grill in place.  There is a back row (towards the back of the bezel) and a front row.
   
   If you are using a "slim" grill, the grill should sit in the middle of these row of nubs. The flattest part of the grill should face the back of the bezel (leaving about 5mm of space behind the bezel).
   
   If you are using the "deep" grill, the grill should sit in front of all the nubs. The flattest part of the grill should face the front back of the bezel (leaving about 12mm of space behind the bezel).
   
    
8. You should now be done.  Attach the bezel to the rack using the installed ears.
   
   If adding/removing the bezel feels tight, you might need to adjust the ear placement.
   
   Slightly loosen the rack bolts, move the ears apart a tiny bit and tighten back down again.  Only a small gap/adjustment should be needed in most cases

Final thoughts

I haven't seen a 10 inch spring loaded bezel on any 3d print site … so this might be a first? (^^;)  Let me know if you've seen one elsewhere as I'm curious if I'm wrong!