Author Topic: Woodpeckers Parallel Guide System Custom Foam Insert  (Read 1653 times)

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Offline edwarmr

  • Posts: 51
Woodpeckers Parallel Guide System Custom Foam Insert
« on: July 20, 2019, 06:09 PM »
I just wanted to share something I came up with for my Woodpeckers PGS. One of the common complaints many have had about the Woodpeckers system is that it needs to be disassembled and reassembled each time it is used. The new TSO product can be used straight out of the systainer but I like the ability to add tracks and store it all in one systainer.

So here’s what I came up with. It’s a custom kaizen foam insert I made that allows the parallel guide system to be stored already assembled. If you need additional track length you can add it on but if not you can use it as is (most cuts I will be making will not require multiple tracks connected).



In order to allow room for calibration of the PGS to your track saw guide rail leave a small amount of extra space in your foam cutout where the track ends (see photo below)



The remaining tracks store directly below the top track to conserve space. I made a finger hole which allows easy access for removing the tracks as well as for removing the narrow stock guide bars. The track connectors are easily accessible and I drilled a small hole in between the two sets of track connectors to hold the allen key. I also drilled holes for the nylon pins that go on the narrow stock guide bars. So that the insert sits nice and flush I installed the Tanos flush mount base insert under the kaizen foam.



The kaizen foam in the lid is a precut insert from kaizeninserts.com



I pitched this idea to Woodpeckers. They seemed to like it but said they don’t know when they would get around to it with all the projects they are currently working on. I told them it might help them out since many people are purchasing TSO’s parallel guides because they are ready to go out of the systainer. We shall see what happens  [tongue].

Anyways, sorry for the long post. I hope this helps for those who want their Woodpeckers PGS to stay assembled in the systainer.


Offline edwarmr

  • Posts: 51
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #1 on: July 20, 2019, 06:37 PM »
This is a previous version that I did that also works but it requires one of the flip stops to be attached to the rail when it’s stored. The lid foam can’t be used with this version as the flips stops sit too close to the lid when closed.



I’m actually selling a couple of my Woodpeckers systainers as I got the new ones with the red handles and t loc latches and I’m willing to include this older version of my PGS insert with the systainers. I will post it in classifieds shortly.

Offline ben_r_

  • Posts: 1192
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #2 on: July 23, 2019, 09:52 PM »
Better than the stock one! Well done!
If at first you don't succeed, redefine success!

Offline edwarmr

  • Posts: 51
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #3 on: July 23, 2019, 10:15 PM »
Thanks Ben!

I’m still hoping Woodpeckers will eventually take this idea. With their CNCs I’m sure they could make it much more precise.

Offline Dusty.Tools

  • Posts: 121
    • Dusty.Tools
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #4 on: July 23, 2019, 11:31 PM »
Nice! I did something similar but for a drawer, which means I can leave 3 of tracks installed.
@dusty.tools

Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #5 on: August 02, 2019, 01:54 PM »
This looks great!  I'm still using the standard foam and putting it away each time.  The only "mod" I made was that I went ahead and slid a connection bar into each track extension, since you inevitably need one for each extension.

Offline ben_r_

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Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #6 on: August 02, 2019, 02:46 PM »
What did you use to cut these?
If at first you don't succeed, redefine success!

Offline edwarmr

  • Posts: 51
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #7 on: August 02, 2019, 04:26 PM »
I have a set of Fastcap/kaizen knives that I use because I use kaizen foam a lot but any utility knife or snap blade knife will work. Just make sure to have a fresh blade or snap off the worn part because a sharp blade makes a nice clean cut in kaizen foam and I’ve found the foam can dull the blade pretty quick.

I’ve bought precut kaizen inserts for my Systainers/TSTAKs and I’ve made my own by making a template. The nice thing with the kaizen knife set is you can use blades of different widths for different tasks. Very narrow blades are good for sharp turns. I used to trace my items with a marker but I’ve found just carefully tracing the object with the knife is more accurate.

 

Offline ben_r_

  • Posts: 1192
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #8 on: August 02, 2019, 04:48 PM »
Have you looked into building a hot wire foam cutter and just buying polyethylene closed cell foam instead of spending high dollar on kaizen sheets?
If at first you don't succeed, redefine success!

Offline edwarmr

  • Posts: 51
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #9 on: August 02, 2019, 05:06 PM »
I had actually never heard of that before but I just watched a video on it and it seemed cool. I do like how kaizen peels in layers though for storing tools. But yeah it’s spendy >:(

Offline ben_r_

  • Posts: 1192
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #10 on: August 02, 2019, 05:17 PM »
I had actually never heard of that before but I just watched a video on it and it seemed cool. I do like how kaizen peels in layers though for storing tools. But yeah it’s spendy >:(
Ah, well, a bit more info then. Kaizen is just a brand name for thin sheets of polyethylene closed cell foam that are glue together. You can buy it in huge sheets of all thicknesses and even a few colors for MUCH less than they are getting for those pre-glued together sheets. And using a hot wire foam cutter to cut it all up can yield some extremely clean results.
If at first you don't succeed, redefine success!

Offline edwarmr

  • Posts: 51
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #11 on: August 02, 2019, 05:22 PM »
Thanks for that info! That’s good to know. So how would you make cutouts on the interior of the foam for your tools? Would you glue layers together yourself and then cut the interior with a utility knife?

Offline ben_r_

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Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #12 on: August 02, 2019, 06:26 PM »
Thanks for that info! That’s good to know. So how would you make cutouts on the interior of the foam for your tools? Would you glue layers together yourself and then cut the interior with a utility knife?
You buy the sheets in whatever thickness you need/want. Cut the shapes out that you need from each layer and then glue the whole thing together with spray adhesive. Theres tons of people in the gun community making custom padding for Pelican cases. Do some googling and youtube searching and youll find all kinds of methods and options.
If at first you don't succeed, redefine success!

Offline edwarmr

  • Posts: 51
Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #13 on: August 02, 2019, 09:03 PM »
Thanks for the tips!

Offline fritter63

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Re: Woodpeckers Parallel Guide System Custom Foam Insert
« Reply #14 on: August 13, 2019, 08:57 PM »
Very nice! I had thought about figuring a way to leave them attached but never got around to thinking it through... too many projects!

Maybe I'll do up a CAM program to CNC these (if I ever get around to it!).

Truth is, the CNC machine has "spoiled" me as a woodworker, and I'm getting ready to expand the machine to a 4x8 capacity, so I can just slap a sheet down and start cutting it.