>>with my original design the extra piece would have been the back. all the math works out with very minimal waste.

Sorry, I overlooked that part. I think it can work and since you have a router suggest a combination of dados and rabbets for the rack. I'm sure you already planned that.

I like heat cable and suspect it would work well in a rack. What I really like about it for a tall rack would be that as much or as little could be run underneat the boxes to achieve any temperatures from top to bottom.

To be fair, I have never used heat cable in a melamine rack. I suspect it would work but have no first hand experience to back it up. It works very well in my Vision rack.

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