Introducing Ryan’s SYS-Stacker Inserts: Router Bit StorageNow a "Digital" ProjectProduction Update: Many of you have been following the evolution of this project -- thanks for the interest! After attempting to perform the CNC work myself (140+ decks), I quickly realized that I had "bit off a little more than I could chew." So, I've switched gears and instead have made the Fusion 360 CAD/CAM files available for purchase. With access to these files, you can go to any good, local CNC shop and have them cut your kit in anywhere from 20 minutes (for a basic SYS1 kit) to approximately 100 minutes (for a SYS4 kit). I've also included assembly instructions in a standalone PDF. If you're interested in the design files, I'm asking $40 USD for those who didn't put in an original pre-order; for those who were generous enough to put in a pre-order, I'm asking for $25 USD. Just PM me if you'd like to purchase.Here, a SYS3 kit is depicted. This new design uses two 9mm platforms for the top and bottom, light but very strong.This new design retains the stepped hole functionality, so you can place 1/2" or 1/4" shank bits. New dogbone design helps to self-center the platforms for assembly.Decks retain stackability, with a simpler design that uses only two risers (plus the handle). Here's an example of the nested Fusion 360 file for the SYS4 kit, which is cut from a single 53x27" sheet. All toolpaths have been fully defined -- just bring your 1/4" down-cut spiral bit!
So, what makes these inserts so cool?
- Mix and match to fit your specific T-LOC Systainer, from SYS1 to SYS4: two deck configurations, and three different “riser kits.” (For optimal configurations to fit your Systainer, see bottom of post.)
- A dual-shank hole design means you can insert your 1/2" and 1/4" router bits into the same hole!
- Each deck is stackable, making it easy to quickly access your bits, no matter how far down you put them.
- Each deck is made from two layers of 9mm thick Baltic birch plywood, offering plenty of rigidity while also saving on weight.
- Incredible capacity: closed decks hold more than 127 bits, and open decks hold 68 bits--limited only by the cutting diameter of your bits.
- Cut with CNC precision, so every piece fits perfectly.
Let's discuss the decks: open or closed?
A closed deck is best for maximizing the router bit capacity, is ideal for smaller Systainers (SYS 1 and SYS2), and also works well as a lower or bottom deck on larger Systainers (SYS3 and up). The open deck serves as a perfect top-level for larger Systainers, and with this open design, you can store particularly tall bits in this area without having to worry about headroom.
What kit is best for my particular Systainer?
See below for my recommended kit, guaranteed to fit. (Note that I have not tested fitment on Systainer Classics; just the T-LOCs.) The below renderings depict my previous design that utilized 30mm thick baltic birch -- the new design is functionally equivalent (save for slightly less holes), and a lot lighter. SYS 1 T-LOC Systainer – Recommended Configuration
Closed deck, small handle, plugs instead of risers. This configuration will accommodate router bits ranging from 70 to 80 mm in total length. SYS 2 T-LOC Systainer – Recommended Configuration
Closed deck, large handle, plugs instead of risers. This configuration will accommodate router bits ranging from 120 to 130 mm in total length. If you’ve got a router bit longer than that, I’d love to see it.SYS 3 T-LOC Systainer – Recommended Configuration
The preferred Systainer for this insert. One closed deck with medium handle and risers, one open deck with small handle and plugs instead of risers. This configuration will accommodate router bits ranging from 68 to 96 mm in total length, and the “open area” will accommodate bits larger than that. SYS 4 T-LOC Systainer – Recommended Configuration
Two closed decks with medium handle and risers, one open deck with small handle and plugs instead of risers. This configuration will accommodate router bits up to 96 mm long under the covered portions, and any bits longer than that can be stored in the open area.