Here is what I did to remidy the problem.

http://www.forcemachinery.com/festoolmods.htm

Now my vacuum gets pulled not the cord which I think is safer anyhow.

I aggree though, I havenet had a problem but a better jack would of been nice. 
I do however love the plug it cord saves me a ton of tangles when switching between sanders.  I want to adapt all my other tools to plug it if I could only get the dang retrofit cord in the us.  Why festool can't import a simple plug is beyond me. I know UL BS but just put it through and make customers happy.

New tools are tight but it will become looser. I have never had a single problem with the plug it cord. I think it is a good idea you can have a cord attached to the vacuum hose and just change the tool with out needing to take the cord of the hose.

I love the plug it cords and will someday have almost every tool I have switched over!

Same here. I am impressed and pleased with the ease of use the Plug-It system gives me. I also plan on fitting all my other tools with this thanks to the small extension you can buy and fit to non Plug-It tools.

I never had the problem of it coming loose from my Rotex. In fact, the first time I got the machine I had a very hard time to take it off. And it wasn't that easy to put it on again too. This got better over time, like people said above.

Nevertheless, I think the OP has a point when he says it is poorly designed. It feels a bit flimsy to me too, the plastic feels too weak and I am worried that if I use it too much  the connector might break. I do hope Festool will improve this design in the future with stronger plastic, a stronger connection and more of a snap-lock feel to it than what it has now.

Btw OP, you shouldn't pull too much on the cord, that is never a good thing. If you feel you need a bigger range you can get a longer 7,5 meter cord instead of the 4 meter standard cord.

 I think the plug it cord is a great addition to the more modern Festool's. The Rotex though is more prone to problems due to the higher current draw. You really need to make sure the connectors are properly mated or you can burn out the plug.

What I really like about the system is it forces me to unplug the tool before replacing the blades.Back in the old days I used to be lazy with the Bosch jigsaw and wouldn't bother unplugging it.

As Frank mentioned it would be nice if Festool designed all tools with one cord in mind rather then having two different style connectors. Another option would be too color code the plug it cord and connector on the back of the tool to help identify which tool gets which cord.

Dan Clermont

I suspect Festool saves(or makes) money with the two cord system. The wiring is probably cheaper for the smaller amperage draw cords so they save on costs there and then they are able to sell more cords while simultaneously claiming safety, by making a two cord system. Pretty slick.

If you start changing over just try to make everything with the higher amp cords, it is what I am in the process of doing.

I like the one cord idea a lot.

Given the high price of Festools, I really doubt that the cost difference is a significant factor.  I think more likely it is just a case of overengineering.  I too would be happy if they put the heavier plug-it on all the tools.

Steve

The larger cord fits where the smaller one does so you really only need the large one.


Tom

As with all things Festool, there is a practical and logical reason for the three cord configurations:

1) The smallest cord is designed to work with lower amp machines like sanders...While you can use the larger plug-it cord with the smaller machine...the reverse is not true.  Using the smaller cord (more flexible) also offers the greatest flexibility when working with the tool.  Imagine trying to sand with a 12 gauge extension cord  (not very flexible).  You would end up fighting with the cord instead of focusing on the task at hand.

2) The larger cord is required for the higher amp consumption machines...UL approval requires it.  This is why you can not use the smaller cord with these machines.  It's the same reason the CTs come with the 20amp pigtail...

3) Non-Plug it cords are for machines that pull so much power that the plug it solution would not be practical....CT, OF2200 or Kapex running at maximum capacity as an example. 

I personally love the system, as it allows me to work without a lot of cords plugged into outlets, as well as not having to plug/unplug machines into my CT every time I change tools.

 

Right you are.  I should have been able to figure that out   

Now, if only I had taken the larger cord with me in the situation I described in reply #36 in this thread, I would not have had to resort to the use of a Makita saw.

Nick,

You can use Techflex to create your own - http://www.techflex.com/prod_PTN.asp.

I have used this or similar products for years in the electronics field, and would be great for this application. 

I bet you are right.  It has been a few years since I bought any, but the flex and the shrink wrap are both fairly expensive.

How does it work on the boom arms?  I have thought about trying the flex, but am still working out how I am going to setup my workflow.  When I am working in the shop, I switch between the 27mm and 36mm hose too often for it to be practical.

I am lucky enough to have one of each size hose always set up, one on each boom arm.  I have two hoses and 4 different extensions. The DeWalt routers use a quick plug set up so I have those with the Festool cords on each arm.

Yeah even just that shrink wrap is really expensive!

The photos below show two PlugIt cords and two receptacles.


This is the high-current cord. It is 16 Ga. SJO cord.




This is the low-current cord. It is 18 Ga. SJO cord. Notice that it also has an extra protuberance that the cord above doesn't.




This is the low-current receptacle (on a Domino). Notice that it has a keyway that corresponds to the protuberance above.




This is the high-current receptacle (on a TS 55). Notice the extra keyway is missing.




That key and keyway is what keeps the low-current cord from being plugged in to a tool that draws too much current for it. The high-current cord, however can be plugged into the low-current receptacles.

The OF 1400 cord and the TS 55 cord are the same, both are high-current cords.


Tom