Author Topic: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'  (Read 32152 times)

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Offline jonny round boy

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Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« on: November 26, 2014, 03:04 PM »
As mentioned earlier today in this thread, two lovely new Sortainers arrived this morning:



It's taken me most of the afternoon, a lot of tool making, and a little bit of swearing, but I've transformed them (plus my original SYS3 SORT/4) into this:





 [big grin] [big grin] [big grin] [big grin] [big grin] [big grin]

The base, top, and uppermost side/shelf section are from the old one along with the original 4 drawers; the two lower side/shelf sections and the two new large drawers are from the new ones.

It's the same size as a SYS5, and should give me some options for moving my hand-tools into the large drawers.


Oh, and with the parts left over I was able to make these two little beauties:



 [thumbs up]

I may end up using one of these, but I will be putting at least one of them on eBay in the next week or so...
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline Greg Powers

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #1 on: November 26, 2014, 03:06 PM »
thats what is so great about a modular system you can create what you want.
Greg Powers
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Offline Sean Ackerman

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #2 on: November 26, 2014, 03:11 PM »
COOL!

What's the weight unloaded?  Loaded?
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Offline GarryMartin

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #3 on: November 26, 2014, 03:53 PM »
What's the weight unloaded?  Loaded?

Monty Python fan?  [wink]

Offline Sean Ackerman

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #4 on: November 26, 2014, 04:03 PM »
Haha!
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Offline 72anthony

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #5 on: November 26, 2014, 04:48 PM »
Sorry for the dumb question, but can you explain what you did? I don't understand what the drawers are fitting into.

I only have t-locs and no sortainers.

Thanks,
Anthony
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Offline Don T

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #6 on: November 26, 2014, 04:52 PM »
You beat me to the question Anthony.
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Offline jimbouk

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #7 on: November 26, 2014, 04:55 PM »
That looks great Jrb. Can you elaborate on how you went about joining em? I fancy giving it a go....
BHC 18, TSC 55REB, OF 1400, MIDI, TS55, TRION, Df500, CSX...

Offline SRSemenza

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #8 on: November 26, 2014, 05:48 PM »
Yes, finally someone actually got Sortainers pulled apart and back together ! OK, other than the swearing, how did you get them apart?

Seth

Offline jonny round boy

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #9 on: November 26, 2014, 05:57 PM »
COOL!

What's the weight unloaded?  Loaded?

Thanks! I don't know on the weight - I don't have any scales big enough to weigh it...

It will live permanently on my Sys-Roll anyway, so the only issue with the weight is lifting it in & out of my van.


Sorry for the dumb question, but can you explain what you did? I don't understand what the drawers are fitting into.

I only have t-locs and no sortainers.

Thanks,
Anthony

Anthony,

The sortainers are made of 3 types of sections: a base moulding, a top moulding, and then the centre section (which is made up of 2 sides & the shelf/shelves). It's modular, so you can add in more centre sections to increase the height. Here's a picture with the drawers removed:



There's an old post HERE with some line drawings that explain (I can't believe that post is from August 2007!!! That means it's taken me over SEVEN YEARS to get around to doing this!!! [eek] ).

The sections are held together by very strong, locking, plastic tabs:



There are 4 tabs on each side, and they all need to be pushed in together. Behind each tab however is a little plastic part that stops it from being pushed back! It's designed to be pushed together & locked, not to be dismantled! It takes a LOT of force to push the tabs back and push the support part out of the way at the same time.

I decided to make some kind of tool to push the tabs in, so used a piece of 6mm MR MDF & cut some notches in it to leave 4 'pins':





I then used this, and a couple of clamps, to push all 4 tabs in together. Unfortunately, it took so much force that this was the result:



Back to the drawing board! I then tried various different methods/materials to come up with something similar that would take the required force, including gluing M5 nyloc nuts to a piece of timber to make the 'pins' (the glue gave way & the nuts fell off [eek]), using the MDF again, but saturating the pins with resin to strengthen it (pins stayed intact, but just sheared off at the edge of the reinforcement), cutting the shape required from a think piece of oak (the oak just crushed), and putting screws in a piece of timber, standing proud.

Ideally, it needs making out of a piece of 6mm thick aluminium, but I don't have any & couldn't get any locally.

Anyway, between the various methods I managed to get all 3 sortainers apart, without damaging any of them. Here's one of them:



The tabs holding the top section are much harder to get to, and caused me some trouble!

I had intended to document every stage, but after all the faffing about I forgot to take pictures at various stages!


That looks great Jrb. Can you elaborate on how you went about joining em? I fancy giving it a go....

Once they're apart, it's just a simple, 2 minute job to push them back together.


Jonathan
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline greg mann

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #10 on: November 26, 2014, 06:16 PM »
Uh, how about doing it over again and videotaping it for us. [poke]
Greg Mann
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Offline jonny round boy

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #11 on: November 26, 2014, 06:39 PM »
Uh, how about doing it over again and videotaping it for us. [poke]

No problem. You just order the 3 sortainers & have them delivered to me, and I'll happily do a video! [tongue]
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline ChrisK1970

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #12 on: November 26, 2014, 06:51 PM »
Hahahahahaha that's great. Cool sorta inter too!
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Offline SRSemenza

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #13 on: November 26, 2014, 11:27 PM »
Excellent!  Just need to perfect the tool.  [thumbs up]

Seth

Offline fuzzy logic

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #14 on: November 26, 2014, 11:39 PM »
Brilliant - thanks for posting.  Just got to wait for the video now...
Richard
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Offline jimbouk

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #15 on: November 27, 2014, 03:05 AM »
Looks great jonny thanks. Now just need to decide on how many and what configuration!
BHC 18, TSC 55REB, OF 1400, MIDI, TS55, TRION, Df500, CSX...

Offline Roadkilled

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #16 on: November 27, 2014, 06:38 PM »
Well done mate can't wait to see it. I love the little sys 1 sortainers  [tongue] rather than letting it go on eBay any chance you'd sell it to a friend  [big grin]

Offline jonny round boy

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #17 on: November 27, 2014, 06:44 PM »
Well done mate can't wait to see it. I love the little sys 1 sortainers  [tongue] rather than letting it go on eBay any chance you'd sell it to a friend  [big grin]

It would depend how much the friend was offering.  [tongue]

 [big grin]
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline Roadkilled

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #18 on: November 27, 2014, 06:59 PM »
 [big grin] I have no idea mate. Txt me but I'm sure you'd get a fortune for it on eBay   [embarassed]

Offline WastedP

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #19 on: December 21, 2014, 11:25 PM »
JRB: Your pics are loaded with great info, but I still have a ton of questions for you.  How has your custom unit been working out?  Do the Sortainers play well with T-Locs in daily usage?  I see the labels on the older parts, but what are you carrying in there?  What are the interior dimensions of the large drawers?

I've been lugging my Makita drills in a T-Loc SYS-4 with a stack of T-Loc minis filling up the other half of it.  I have been picking up some installation slack over the last week with that setup, and I found myself needing just my impact driver and some bits without opening up the whole kit.  I kept thinking of this Frankentainer as a better approach.  I don't see myself making the mega version like yours, but the five-drawer Tanos unit looks good.

Again, I appreciate the great pics you posted, but any other info you can give me would be a big help.

Offline rizzoa13

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #20 on: December 22, 2014, 12:27 AM »
Seems like the perfect tool to have 3-d printed!

Offline jobsworth

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #21 on: December 22, 2014, 03:03 AM »
JRB,

You are a cleaver fellow (see Im learning English  [big grin] ). Would you bring them to the next get together so we can have a look at them.

Amazing the things you come up with...

Offline jonny round boy

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #22 on: December 22, 2014, 07:13 AM »
Seems like the perfect tool to have 3-d printed!

3D printing wouldn't really be appropriate, for a couple of reasons; firstly, size - it needs to be about 400mm long, which is much bigger than most 3D printer beds. Additionally, it would use a LOT of filament! Secondly - 3D printed plastic simply wouldn't be strong enough.

The tool is actually a very simple 2D shape, and could be made easily & cheaply from some 6mm thick 50-60mm wide aluminium bar. That's what I'd have used if I'd had some to hand.
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline jonny round boy

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #23 on: December 22, 2014, 07:14 AM »
JRB,

You are a cleaver fellow (see Im learning English  [big grin] ). Would you bring them to the next get together so we can have a look at them.

Amazing the things you come up with...

Sure, I'll bring them. As for the things I come up with, I don't think I can take credit for thinking this idea up, I'm sure others have toyed with the idea before!
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline jonny round boy

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #24 on: December 22, 2014, 07:23 AM »
JRB: Your pics are loaded with great info, but I still have a ton of questions for you.  How has your custom unit been working out?  Do the Sortainers play well with T-Locs in daily usage?  I see the labels on the older parts, but what are you carrying in there?  What are the interior dimensions of the large drawers?

I've been lugging my Makita drills in a T-Loc SYS-4 with a stack of T-Loc minis filling up the other half of it.  I have been picking up some installation slack over the last week with that setup, and I found myself needing just my impact driver and some bits without opening up the whole kit.  I kept thinking of this Frankentainer as a better approach.  I don't see myself making the mega version like yours, but the five-drawer Tanos unit looks good.

Again, I appreciate the great pics you posted, but any other info you can give me would be a big help.

I think I've found the topic for my next video review!

I don't have the internal drawer dimensions to hand, but there are many threads on here which give them. Do a search and I'm sure you'll find that info.

The systainers are great for most powertools, but I've found that, for handtools, they're not so practical. Having lots of small items in various systainers means that you either have to have a large floor or worktop area to spread them all round, so you can leave them all open, or you spend more time un-stacking & re-stacking them to get to the tool you want, than you do actually using the tools.

It was a friend and work colleague, Jon (aka Roadkilled) who first introduced me to the idea of using sortainers instead. His set-up for his hand tools is 3 sortainers on a roll-board. I just took it a step further, and did away with some of the 'dead' space where they're connected together.

I'll try to put a video together over the holidays, showing what I keep in there.
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline jimbouk

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #25 on: December 22, 2014, 12:25 PM »
Look forward to that jrb
! :)
BHC 18, TSC 55REB, OF 1400, MIDI, TS55, TRION, Df500, CSX...

Offline SRSemenza

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #26 on: December 22, 2014, 06:48 PM »
Large drawer inside......

       3 1/8" tall

       13 3/4" wide

       11 1/8" front to back  about 1/4" less in the divider support locations and about 1" x 1" x 1 1/4" for the latch protrusion.

Seth

   

Offline SRSemenza

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #27 on: December 22, 2014, 06:51 PM »
JRB,

   What is the total height of the triple lg drawer unit ?

Seth

Offline jonny round boy

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #28 on: December 22, 2014, 07:16 PM »
JRB,

   What is the total height of the triple lg drawer unit ?

Seth

It's exactly the same size as a sys5.
Festoolian since February 2006

TS55R EBQ saw - CTL26 - CTL Mini - OF1400EBQ router - KS120 Kapex SCMS - ETS150/3 sander - RO90 sander - DF500 Domino - PDC18/4 drill - PSC420 jigsaw - OFK500 trimmer

Wish list (in no particular order!): Anything not listed above....

Offline SRSemenza

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Re: Introducing: The SYS 5 SORT/6, aka 'MegaSortainer'
« Reply #29 on: December 22, 2014, 10:05 PM »
JRB,

   What is the total height of the triple lg drawer unit ?

Seth

It's exactly the same size as a sys5.


Excellent! Fits right into my set ups.

Seth