great job matt.
cant wait to see more.

how much do it cost in total for the aluminium

That is great Matt!
Perfect for  shop/home use, what do you think you had into the whole thing $ ?
I like it!

In terms of execution, I did the design using Microsoft Visio (am a corporate worker by day). The stick man type isometric picture is important to to make sure you count the right number of pieces. I could have done this in Sketch-up I guess but would need to learn how to use it, so this worked fine (I did see there is already some profile inn the 3d warehouse. The stuff I used is Bosch Rexwroth


The costings are as follows:-

Item	£	$
19.85m of Aluminium	£205	$325
Castors	£44	$70
60 core bolts	£29	$46
Ply 2 sheets 12mm WPB	£32	$52
12x 350mm drawer slides	£72	$115
Total	£382	$608

So not cheap but will last, is configurable, can still change it a bit, wont rust or warp, very easy to bolt additions on. I have found that planning it out is very important. I have a blade to cut Alu on the KAPEX but wouldn't want to do lots of it, so have worked out all the lengths first and KJN cut it. They are pretty accurate, I would say to at least 0.5mm

I agree, I don't think its too bad either, total cost in vat and delivery of all the components to make what you see in the pics (exluding runners and plywood), the drill press and a router table which I will do a progress post on soon was just over £600.

The cost of getting good quality timber to build it all wouldn't be hugely less, since the alu is 50% of the cost, runners etc soon add up which you need either way. I just prefer the rigidity and fixed nature of alu (no warping etc) for this sort of thing. Plus its light.. I could quite easily lift the complete subframe and had to to get some of the bolts in.. I would struggle with wood. Also having all the pieces of alu cut to size as part of the cost is a major time saver!!

Thanks Matt, that price here is 1 sysport, so I think you did great!

Please see below pictures, plus I have included a couple of the KAPEX fixing, its leveled using the 4 threaded bars (the KAPEX platform is suspended) and then once at the exact height, locked into place using the quick connectors)





Mock up of KAPEX platform


Actual platform

I did the iso by freehand, visio doesn't do much (other than to be able to set a line at 60/30 degrees)

pure hawtness.  If I ever have the space, I'll definitely do something like this.

No it just rests, my precise measuring paid off, it a tight fit, has to be dropped on perfectly vertical. It's quick to take off, then just bolt the legs on. Took a while to get the legs off as there is a nyloc bolt. But if you were just popping off for a quick job I wouldn't bother, could probably convert it back in 5 mins or so

Wintu   You could go do a search for 8020 on EBay and use their store to see what you need. This is a location for alot of their job left overs. I order from them often you Will lamazed at their inventory of goodies. The have T slot Alum rail in fractional and metric. They carry the 4545 and the 4590 series rails used above

Sal

Finally got around to just about finishing it. As others will know, there are a few shortcomings on the Festool CMS router module, one being to no fine adjustable way to move both faces of the fence back (just the right hand one can be recessed to use the fence planer style) plus keeping the fence parallel to the front of the module (and the sliding carriage I have) is a manual effort, so since Incra now do a metric version of their fence I have combined it into the design




Router bit storage in the 2 drawers


The Wixey digital readout was another addition.. has been great, wind the bit up to be level with the table.. press the "zero" button and you can quickly set the bit height to the nearest 100th of a mm


OF2200 mounting view


The Wixey does fractions for our imperial friends :-)


Onto the Incra.. I mounted it on pivots so it lifts clear of the table, in case I want to use a template bit and want a free surface.. or want to use the festool fence


Hinge detail


Incra LS positioner deployed, the red lever locks the fence in place one at the desired distance, it has an intermediate position for fine adjustment


Front view of the fence arrangement. I have the "Wonder" fence attached, which in addition allows you to adjust the mouth for the large bits, and move the left and right side back and forth to change their depth


To adjust the depth of the fence wings, there is a wedge system which allows very fine control


The whole fence can be moved back and forth (see the earlier pic with the big red locking lever), this knob is for fine adjusting


Festool fence can be used when the Incra has been pivoted away


I didn't find the CMS plate alignment was perfect with the surrounding CMS framework, so I used some profile below and drilled (carefully!!) through the CMS plate. These two countersunk socket screws bolt into the profile below and pull the whole assembly dead flat


Onto my CMS+ MFT sysport.. I created a cabinet below the CMS mount for my spare module to go in.. simple hinge door


The plate+tool not in use can be stored here


Side view


Drawers extend to allow access to systainers


Drill stand completed


Eagle eyes might spot the Zobo Festool drillbits in the drawer :-)



A couple of random additions... I was struggling to find a good way to put wheels on my workbench and wanted to take advantage of the stability of having the bench on the floor.. but be bale to move it. I found some jockey wheels that have a side wind mechanism (rated at 1000lbs each wheel).. so whilst not pretty, do a good job. Once wound down the castors go below the bench so they can rotate (the winding mech. has a travel of over 12")


2nd pic.. they wheels on ebay were £15 each so not much more that a good quality castor


KAPEX by night!

The Wonderfence profile if blocked off on one end and the other has a 50mm port (you can see the black 90deg bend on the left hand side for extraction) and where the two fences split to adjust for bit size, there is also an inner lining to improve extraction.

All that said, I tend to extract through the OF2200 as there is a pretty good dust shroud and get a good throughput with a 38mm hose

Yes will probably do that... should work pretty well

Fabulous job Matt!  It looks like a great addition to your shop.

Those aluminum profiles are available in the US from 80/20 and they will even cut them to length for you.
Steve

Matt,

Reading throught he thread.  Very impressive. 

I like what you have done with those profiles.  I did have one question though... Where is the 45x90 profile located in the sysport w CMS and MFT?  I see you call out 3 pieces and I dont see where they are in the drawing.  They are essentially 2 of the same profile togehter??

Thanks,

Mike