System Deep Dive

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minute read

Why We Built Our Own Rack

Why We Built Our Own Rack

Why We Built Our Own Rack

The big box stores had options. We tried them. Here is why we ended up designing our own from scratch.

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Before Wally existed, we went shopping.

We looked at the tote racks available at the big box stores. We looked at what DIYers were building with two-by-fours and plywood. We looked at the wire shelving systems, the plastic track systems, and the various wall-mounted options that promised to solve the garage storage problem.

None of them was good enough. Not even close.

The Problem with What Was Out There

The metal tote racks from the hardware stores had a specific set of problems that became obvious the moment you tried to use them. They were hollow, lightweight metal that leaned under any real load. Assembly was fiddly and the finished product never felt solid. And they sat on the floor, which meant dust and debris collected underneath them, and in a Calgary garage, that means salt and water and everything else that comes in off the driveway in November.

The bigger problem was the fit. The totes did not sit properly in the racks. There was empty space on the sides, gaps between bins, and a general looseness that made the whole system feel temporary. You could see that the rack was not designed around the tote. It was designed around a general idea of a tote, and the actual product was just supposed to make do.

The DIY wooden versions had their own issues. Two-by-fours from the lumber yard are almost never straight. You can build a shelf that looks level when you finish it and is visibly warped by the following spring. Wood and Calgary winters are not a good combination. The snow and water that comes in on boots and vehicles gets into the wood, and over time it warps, swells, and in the worst cases, goes moldy. A wooden shelf that sits on a garage floor is essentially a sponge waiting for its moment.

And all of these options, the metal racks and the wooden shelves alike, had the same fundamental flaw: they sat on the floor. The floor of a Calgary garage is not a clean, stable environment. It is wet in winter, dusty in summer, and difficult to clean around anything that is sitting on it.

The Decision to Build Something Better

We decided that if we were going to build a storage system worth putting in someone's home, we had to start from scratch. The constraints were clear: it had to be strong enough to hold real weight, it had to get off the floor entirely, it had to be designed around the actual totes we were using, and it had to survive Calgary winters indefinitely.

The answer was solid steel.

The Engineering Behind the Wally Rack

We designed the Wally rack specifically around the HDX 64L Tough Totes from Home Depot. These are the best totes available for garage storage: tough, practical, easy to label, and sized well for the kind of gear most Calgary homeowners are storing. The HDX totes have a manufacturer-rated capacity of 75 pounds. We designed our rack to match that rating, so the weakest point in the system is never the rack itself.

The racks are solid steel, not hollow tubing. They do not flex, lean, or loosen over time. Each rack is designed so the tote sits flush and secure, with no wasted space on the sides and no gap between bins. When a tote is in a Wally rack, it is in the rack. It does not rattle, slide, or shift.

The mounting system is what makes the whole thing work. The steel racks attach to a three-quarter inch plywood backing, which is itself secured directly to the wall studs using the best structural fasteners available. The load path goes from the tote, to the rack, to the plywood, to the studs. Every connection in that chain is engineered to hold. The result is a wall system that feels, and performs, like it was built into the house.

Because the entire system is wall-mounted, the floor underneath is completely clear. You can sweep. You can hose down the winter salt. You can park right up to the wall without anything in the way. The critters and the dust and the Calgary meltwater have nowhere to collect.

The 10-Year Warranty

We back the Wally system with a 10-year warranty on parts and labor. Not because we expect things to go wrong, but because we are confident enough in the engineering to put that in writing.

A garage storage system should not be something you replace every few years. It should be infrastructure. Something you install once, use for decades, and never think about again except to appreciate that it works. That is what we built, and that is what the warranty reflects.

The Payoff

The racks you can buy at the hardware store were designed to be cheap and easy to sell. We designed ours to be strong and impossible to ignore once you have seen them in a finished garage.

Solid steel. Off the floor. Built around the best totes available. Secured to your studs. Guaranteed for 10 years.

That is the Wally rack.

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Subscribe to our newsletter for the latest blog posts and exciting company updates!

By clicking Join Now, you agree to our Terms and Conditions.

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By clicking Join Now, you agree to our Terms and Conditions.