Author Topic: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers  (Read 32665 times)

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Offline ryanjg117

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Introducing Ryan’s SYS-Stacker Inserts: Router Bit Storage
Now a "Digital" Project

Production 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.

« Last Edit: April 21, 2017, 02:22 AM by ryanjg117 »
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Offline Albiski

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #1 on: January 17, 2017, 01:43 AM »
Let me know when you're ready.

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Online epicxt

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #2 on: January 17, 2017, 01:47 AM »
You know I'm in! Set aside an appropriate systainer as well! These look great!![emoji106][emoji2]
n = number of Festools I've got.  (n + 1) = Festools I want

Offline lawhoo

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #3 on: January 17, 2017, 02:03 AM »
Very impressive. I'm in for a Sys 3 or 4 set.

Offline davlen

  • Posts: 2
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #4 on: January 17, 2017, 02:29 AM »
Hi,

Great design!
Two questions:
1) Shipping to France will be possible ?
2) Can you made these inserts for european 8 and 12mm shank ?

David.

Offline Alan m

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #5 on: January 17, 2017, 06:22 AM »
pritty sweet.
not sure i would need that many bits on site  but im all for organisation.

would some kind of plastic like hdpe be better than ply. im thinking about moisture rusting the shanks. is making the holes tight
"A pessimist sees the difficulty in every opportunity; an optimist sees the opportunity in every difficulty."
- Sir Winston Churchill (1874-1965)

Offline Jamie_MA

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #6 on: January 17, 2017, 09:01 AM »
Great Job  [thumbs up] [thumbs up] [thumbs up]


Good luck with the Pat Pen!!!!

Offline promark747

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #7 on: January 17, 2017, 09:34 AM »
Put me down for a Sys 3 configuration, thanks!

Offline Stoli

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #8 on: January 17, 2017, 09:49 AM »
Can't tell if you're serious about the patent pending on the dual hole idea, but @Rick Christopherson has you beat on the prior art in this thread:  http://festoolownersgroup.com/member-projects/router-bit-storage-cabinet/msg339189/#msg339189
« Last Edit: January 17, 2017, 09:58 AM by Stoli »
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Online Peter Halle

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #9 on: January 17, 2017, 10:00 AM »
I don't know how long this thread will last here (it could be considered a competing project and using this forum for advertisement and sales might be an issue (not to be decided by me) but additionally I would offer caution on using the FOG logo on your products for sale without the prior permission of Festool USA. 

Peter
Disclaimer:  I have been involved with the development of some TSO Products.  I have offered thoughts and ideas freely.  I am not paid but I may receive products during the development process or afterwards.

Offline Rick Christopherson

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #10 on: January 17, 2017, 10:09 AM »
Nice idea for portable bit storage. 

Can't tell if you're serious about the patent pending on the dual hole idea, but @Rick Christopherson has you beat on the prior art in this thread:  http://festoolownersgroup.com/member-projects/router-bit-storage-cabinet/msg339189/#msg339189

Yup. Built the first one probably around 20 years ago after noting the limitations of the one I built before that for my father's shop before he/we began hording more router bits. Proposed it to the Woodworker's Journal over 15 years ago, and finally made the final iteration when I did the FOG writeup.

Offline ryanjg117

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #11 on: January 17, 2017, 10:15 AM »
Can't tell if you're serious about the patent pending on the dual hole idea, but @Rick Christopherson has you beat on the prior art in this thread:  http://festoolownersgroup.com/member-projects/router-bit-storage-cabinet/msg339189/#msg339189

Not serious about the "patent pending lingo." I'll update the post to eliminate confusion.
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Offline Goneshootin88

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #12 on: January 17, 2017, 10:47 AM »
I'm in for a sys2 setup. Can you ship to Hawaii?


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Offline tmccowan

  • Posts: 16
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #13 on: January 17, 2017, 01:51 PM »
Looks great! I'm interested.

Offline mculik5

  • Posts: 52
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #14 on: January 17, 2017, 10:02 PM »
Very cool!

Please send me the PayPal details. Interested in the SYS2 option.

Also, separate questions:

1. Where do you get 25mm plywood? Or do you make it yourself from thinner sheets?
2. What kind of CNC machine do you use?

Thanks!

Offline ryanjg117

  • Posts: 72
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #15 on: January 17, 2017, 11:52 PM »
Thanks for all of the comments and PMs. If you've either messaged me or expressed interest in this thread, I have sent you a PM to confirm you're on the pre-order list, and will follow up with additional details as I get closer to CNC time.

Also, Eric Brandt brought up a great question about Systainer Classic compatibility. I'm willing to undertake the design changes necessary to make the inserts backward compatible with Systainer Classics (if it can be done with minimal reengineering), but I don't actually own one. If anyone is local to the Seattle area and has a Classic they can part with for a couple weeks, please let me know.
Festools - TS55, OF1400, ETS 150/5, Pro5 LTD, LS 130, Domino DF500, CT36 w/Boom & Dust Deputy, RipDogs, Qwas Dogs, CXS, walls of systainers, custom JumboMFT

Online epicxt

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #16 on: January 18, 2017, 01:22 AM »
Hey Ryan- I've got a classic at the jobsite that I'm just using for storing glue and epoxy. If you want to swing by anytime this week or weekend you can grab it. Text me first. Cheers!
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Offline UncleJoe

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #17 on: January 18, 2017, 08:39 AM »
I am interested in a sys 2 or sys 3. I also agree with the use of a synthetic material if possible. I love all the thought and effort that went into this. I did not read all the threads regarding this but wondered if a small tray/well area would be useful to store bearings and hex keys and other little things we end up needing with our routers and bits.
I am not young enough to know everything!

Offline Runhard

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #18 on: January 18, 2017, 10:27 AM »
@ryanjg117

I'm in for a Sys 3 setup. What are the chances of you changing some of the 1/4" holes to accommodate 8mm bits? I guess that it wouldn't be too hard for me to drill the holes out for my 8mm bits.

Thanks,

Daniel
Daniel

Offline JSlovic

  • Posts: 91
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #19 on: January 18, 2017, 11:59 AM »
Ryan,
I'm in for a sys 3 configuration
Thanks
jack

Offline ben_r_

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #20 on: January 18, 2017, 12:24 PM »
Man thats a lot of router bits to carry around! I cant imagine owning or needing that many! Cool idea though.
If at first you don't succeed, redefine success!

Offline ryanjg117

  • Posts: 72
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #21 on: January 21, 2017, 01:59 PM »
Thanks for all of the interest and pre-orders. I've updated the post with more pre-order details, and also attempted to answer questions received below:

Will these fit Systainer Classics?
I'm looking into that now, and will test fitment after I have the first prototype CNC'ed. Should be some time in February. If I can make minimal modifications for backward compatibility, I will, and I'll update this post when it happens.

Would you be willing to offer these with 8mm or 12mm? (Or some other shank size?)
Sure - the redesign effort is minimal for changing the size of the router bit holes. Send me a PM with your specific design changes, and your home address, and I can get you a shipping quote. (Shipping might kill the deal here, if you're international.)

I wish you could make this in a composite or HDPE, rather than plywood.
I've looked into HDPE or a millable composite like RenShape as an alternative, and unfortunately, it is cost-prohibitive. An HDPE sheet in 25mm thickness, for example, runs over $500, compared to 25mm baltic birch at about $80 per sheet. If you've got an idea for a better material that is available in 25mm thickness and doesn't break the bank, I'm all ears.
« Last Edit: January 25, 2017, 11:53 PM by ryanjg117 »
Festools - TS55, OF1400, ETS 150/5, Pro5 LTD, LS 130, Domino DF500, CT36 w/Boom & Dust Deputy, RipDogs, Qwas Dogs, CXS, walls of systainers, custom JumboMFT

Offline ryanjg117

  • Posts: 72
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #22 on: January 25, 2017, 11:50 PM »
01-25-2017 Production Update

I'm happy to report we're up to almost 30 pre-orders -- what a response! This might end up being a little more than a Saturday project after all.  [eek]

I've placed an order for a gallon of General Finishes Enduro Pigmented Poly, color matched to Festool's RAL 6018 yellow/green. It's over $100 a gallon shipped, but sprays well with my Apollo HVLP kit and doesn't require a sanding sealer. I'll post pictures once I get to atomizing!

My friend and professional woodworker, Darrell Peart, has generously offered to let me use his dual-spindle CNC machine for this project. Be sure to check out his website if you're a fan of Greene and Greene.

I'll post more production updates (and pictures) as meaningful progress is made.
Festools - TS55, OF1400, ETS 150/5, Pro5 LTD, LS 130, Domino DF500, CT36 w/Boom & Dust Deputy, RipDogs, Qwas Dogs, CXS, walls of systainers, custom JumboMFT

Offline Claimdude

  • Posts: 301
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #23 on: January 26, 2017, 08:32 AM »
Ryan,

I will take the single deck SYS 1 recommended configuration you show at the top of this thread at $32 CONUS.

Thanks
Jack Lemley

Offline Sparktrician

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #24 on: January 26, 2017, 01:00 PM »
How about one full deck for 1/2", and another split equally between 1/4" and 8mm?  Possible?   [unsure]
- Willy -

 "Remember, a chip on the shoulder is a sure sign of wood higher up." - Brigham Young

Offline dlyons41

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #25 on: January 26, 2017, 07:35 PM »
Ryan, I am interested in a SYS 4.  Let me know what I need to do to make it happen.  Thanks, Doug

Offline Horio

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #26 on: January 26, 2017, 11:06 PM »
Ryan,

Would it be possible to do a SYS-3, with the upper open deck configured for 8mm & 1/4 inch (dual shank holes or split half-half as suggested 2 posts up maybe)?  Thanks for offering these sweet inserts to FOG!
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Offline ryanjg117

  • Posts: 72
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #27 on: January 27, 2017, 09:12 PM »
How about one full deck for 1/2", and another split equally between 1/4" and 8mm?  Possible?   [unsure]

Sparktrician, sure. Send me a PM and note your modifications and I'll add you to the pre-order list.
Festools - TS55, OF1400, ETS 150/5, Pro5 LTD, LS 130, Domino DF500, CT36 w/Boom & Dust Deputy, RipDogs, Qwas Dogs, CXS, walls of systainers, custom JumboMFT

Offline ryanjg117

  • Posts: 72
Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #28 on: January 27, 2017, 09:13 PM »
Would it be possible to do a SYS-3, with the upper open deck configured for 8mm & 1/4 inch (dual shank holes or split half-half as suggested 2 posts up maybe)?  Thanks for offering these sweet inserts to FOG!

Yep - shoot me a PM, note your modifications, and I'll get you on the pre-order list.
Festools - TS55, OF1400, ETS 150/5, Pro5 LTD, LS 130, Domino DF500, CT36 w/Boom & Dust Deputy, RipDogs, Qwas Dogs, CXS, walls of systainers, custom JumboMFT

Offline Cheese

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Re: Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers
« Reply #29 on: January 28, 2017, 02:17 PM »
How about one full deck for 1/2", and another split equally between 1/4" and 8mm?  Possible?   [unsure]

Would it be possible to do a SYS-3, with the upper open deck configured for 8mm & 1/4 inch (dual shank holes or split half-half as suggested 2 posts up maybe)?  Thanks for offering these sweet inserts to FOG!

Hey Ryan,
Why not consider using/supplying 1/2" to 8mm Delrin or nylon bushings. That way using the same layout you have now would accommodate 1/4", 8mm & 1/2" router bits. It would also allow the end user greater flexibility in the placement or rearrangement of router bits. [smile]