Colony Cage Construction Protocol

Materials and Equipment Needed

1. 19.5 quart Rubbermaid storage containers with lids 
2. Dremel tool, cutting guide attachment, and multipurpose bit
3. Extension cord
4. Cutting template
5. Quick-clamps
6. Orange clamps
7. Masking tape
8. Utility knife
9. Thrips screening (thinner screening works best)
10. Hot glue gun and glue sticks
11. Aluminum foil (optional)
12. Rotary cutter
13. Weatherstrip (3/4" foam-Lowes is most likely to have this size)
14. Utility baskets (these can be purchased from Dollar General although the store will not accept the P-card)

Safety Issues

Safety glasses should be worn when working with the Dremel tool. Caution should be used with the Dremel tool, the utility knife, and the glue gun.

Time Required

Varies with number of cages and steps to be performed.  Cutting plastic with the Dremel tool requires considerable clean up, so allow extra time for these steps.

Procedure

Step	Image
Clamp template to side of container and clamp container to the lab bench.
Tape template to container to prevent cutting guide from slipping underneath the template.
Place multipurpose bit in Dremel tool and attach the cutting guide.  The cutting guide will be held against the circle in the template to form a smaller hole.
Set the Dremel tool on speed 2 or 3 and carefully insert the bit into the plastic towards the inside of what will be the hole.
Move the bit outwards until the cutting guide contacts the template and cut out the circle.  If the plastic begins to melt rather than cut, slow down either the Dremel tool speed or how fast you are moving the bit.
Cut out both holes, then repeat on other side of container.  Clean the plastic scraps off with a utility knife.  Remove plastic scraps from container before proceeding to the next step.
Cut a piece of screening large enough to cover the hole, allowing for a seam of glue.
Run a bean of hot glue (low temperature) around one of the holes.  Place screening on top of the glue and press screening into glue to seal screening completely.  This may be done carefully with fingers or a ball of aluminum foil.
Trim screening with rotary cutter as shown in photo for lids below if necessary.  Set completed container aside.
Cut the center out of the lids with the Dremel tool and cutting guide.  On the underside of the lid, plastic supports on the corners may need to be trimmed with a utility knife to make room for the glue.
Glue screening to the lid with the hot glue gun and trim as needed.
Place weatherstrip around all four sides of the inside of lid.  Pieces of weaterstrip should not have thrips sized gaps between them.  Set completed lid to the side.
Cut handles on utility baskets even with the main part of the basket.  The handles prevent the baskets from sitting inside the larger containers.