Author Topic: Plug-It SYSTEM HACK! Bringing non-Festools into the fold  (Read 17665 times)

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Offline Joseph C

  • Posts: 266
    • Integrity Design+Build
I've always been supremely frustrated whenever I have to switch from a Festool Plug-It cord to a non-Festool cord.
When scribing, I use a Bosch 1594 planer and a Porter Cable mini-belt sander.  Both connect to my DC hose, but the tangle of plugging/unplugging is a mess!

I had a rare bit of free time this afternoon, and have successfully converted both to the Plug-It system  [thumbs up]

My local dealer stocks the Festool tool end replacement part.  I thought that I might have to do a more extensive modification of the tools with a Dremel, but the process was surprisingly simpler.

I found that the wings of the Festool plug, with just a little modification, fit around the part that holds the tool's cord reinforcement.  I  used epoxy paste to mold the tool casing and Festool plug -  I assembled all together, then disassembled the plug part while the epoxy dried (for future servicing,) then reassembled.  I used insulated butt splices for the connections.  After it was all together I packed a little more epoxy paste between the outside of the tool body and the back of the plug to stiffen things up.

I've seen some other UK/EU members use a NAINA part for this, forming a whip, and I'd love to see what other members have come up with!

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89639-1
TS75, OF1010, PS300, Domino500, MFT/3, CT22 + WCR, CT MIDI, RS2e, RO150, ETS150, DS400, RO90, Grex 2" micropinner (festool green), and packing everything else into systainers, too.

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Offline Joseph C

  • Posts: 266
    • Integrity Design+Build
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #1 on: July 05, 2013, 10:25 PM »
89641-0
TS75, OF1010, PS300, Domino500, MFT/3, CT22 + WCR, CT MIDI, RS2e, RO150, ETS150, DS400, RO90, Grex 2" micropinner (festool green), and packing everything else into systainers, too.

Offline Jeff R Johnson

  • Posts: 95
    • Tried and true woodworking
Re: Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #2 on: July 05, 2013, 11:39 PM »
Nice. I love that little pc sander. It's the perfect size for carrying in the van. I gotta make this mod to mine. Do you have the part number handy?
Jbsurfaces.com

Offline Joseph C

  • Posts: 266
    • Integrity Design+Build
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #3 on: July 06, 2013, 02:03 AM »
89663-0
TS75, OF1010, PS300, Domino500, MFT/3, CT22 + WCR, CT MIDI, RS2e, RO150, ETS150, DS400, RO90, Grex 2" micropinner (festool green), and packing everything else into systainers, too.

Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #4 on: July 06, 2013, 11:46 AM »
Wow..that is simple..think I will give it a try! Thanks for the post.

Offline Richard/RMW

  • Posts: 2016
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #5 on: July 06, 2013, 12:33 PM »
Joseph, that is awesome! I have, uhhmnnn, "imported" a few of the whips to convert tools but I like your solution much better.

Do you have the part number for the piece you used?

Thanks,

RMW   
As of 10/17 I am out of the Dog business and pursuing other distractions. Thanks for a fun ride!

Offline NERemodeling

  • Posts: 608
    • New England Remodeling, LLC
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #6 on: July 06, 2013, 12:36 PM »
very cool!   i have been wanting to do this to my HL850 for some time now but didnt want to void the warranty (sept this year)     i just sent it out for a little tune up service and to address a few possible issues before the warranty expires, when i get it back i be doing something similar to this!

i could tell by looking at the HL that i would have to mount the plug it lead mostly outside the tool (like yours) and knew i would have to glue it some way to the tools housing to keep it secure.. looks like your epoxy paste is the perfect fit for the job.. nice detail about separating the housing to let it dry so the tool can be serviced down the road!

thanks for sharing!

John
CT26  -  (2) Midi  - Planex - Kapex -  Domino 500  -  Carvex  -  TS55EQ -  Rails; 800, 1080, 1400(holy rail), 1900, 3000 -  OF1400 - OF1010  - LR 32 - RO 150 - RO90 - RAS115 - ETS125 - DTS400 - LS130 -  EHL65 - HL850 -  MFT1080 - (2) MFT800

Offline Joseph C

  • Posts: 266
    • Integrity Design+Build
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #7 on: July 07, 2013, 08:03 PM »
As far as the part number, you can look it up on EKAT. I used a TS55 part for the planer, thinking it might be a little heavier duty, but the leads looked to be the same gauge as the lighter part I used for the sander.

As far as the epoxy, I keep a stock of Mohawk on hand because of the colors, but there are a number of these machinable two-part epoxy sticks available. Stay away from JB Weld or anything else that actually contains metal, obviously.
TS75, OF1010, PS300, Domino500, MFT/3, CT22 + WCR, CT MIDI, RS2e, RO150, ETS150, DS400, RO90, Grex 2" micropinner (festool green), and packing everything else into systainers, too.

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #8 on: October 23, 2013, 12:32 PM »
I was going a little crazy, ready to order parts from Europe (again), and then I found this thread.  What a great idea, can't believe I didn't think of it myself!  Just ordered a few of the ts55 sockets to install on various tools. 

Part number by the way is 491725, and that's for American 110 V.

Thanks again!
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline elimelech12

  • Posts: 376
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #9 on: October 23, 2013, 10:49 PM »
Awesome man thanks
Sold my tools but kept a few Fes-tools...just in case.

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #10 on: October 29, 2013, 02:32 PM »
So I got my plug it sockets and had some free time today to hack up my makita track saw.  I had to nip off the tabs on the back of the plug it adapter because the makita cord comes sideways out of a hole that doesn't have a seam in it, but all in all it was a pretty simple project.  One of the wires coming out of the socket was too short, but nothing a little splice couldn't fix.  The only thing I didn't get was that all of the plug it cords i have, as well as all of the festool tools i have, have a triangular notch cut out of the socket, but the plug it socket that I got from festool, which was listed as a replacement part for the ts55, doesn't have that.  As a result I had to cut off the matching notch on one of my plug it cords to fit into the socket I'd just put in the track saw.  Anybody know anything about this?
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline Richard/RMW

  • Posts: 2016
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #11 on: October 29, 2013, 02:56 PM »
So I got my plug it sockets and had some free time today to hack up my makita track saw.  I had to nip off the tabs on the back of the plug it adapter because the makita cord comes sideways out of a hole that doesn't have a seam in it, but all in all it was a pretty simple project.  One of the wires coming out of the socket was too short, but nothing a little splice couldn't fix.  The only thing I didn't get was that all of the plug it cords i have, as well as all of the festool tools i have, have a triangular notch cut out of the socket, but the plug it socket that I got from festool, which was listed as a replacement part for the ts55, doesn't have that.  As a result I had to cut off the matching notch on one of my plug it cords to fit into the socket I'd just put in the track saw.  Anybody know anything about this?

There are 2 different plugit cords, one is for tools that draw less power and the conductors are smaller. The TS55 comes with the heavier cord, whereas the RO90 (for example) comes with the lighter cord. If I recall correctly this is the cord with and knotch and a tab, the heavier cord only has the notch.

I would not use this setup until I had checked the power draw on the tool and the required conductors for that amperage!

RMW
As of 10/17 I am out of the Dog business and pursuing other distractions. Thanks for a fun ride!

Offline Richard/RMW

  • Posts: 2016
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #12 on: October 29, 2013, 03:11 PM »
I ran out to the shop to get a couple pictures to clarify this. On the Rockler site they sell both 16 and 18 gauge cords:

95013-0

This is the 16 gauge cord that came with my TS55:

95015-1

This is the 18 gauge cord that came with my Carvex:

95017-2

Basically they designed it so the heavier cord (16 gauge) works with all tools but the 18 gauge cord only fits tools with a lower amp draw.

Hope this helps.

RMW
As of 10/17 I am out of the Dog business and pursuing other distractions. Thanks for a fun ride!

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #13 on: October 29, 2013, 04:36 PM »
Helps a lot in fact!

All of my festools fit into the lower-draw category for sure, hence the discrepancy.  I'll be sure to pick up an appropriate extra as I like having one per tool anyway.  I'm gonna grab my little PC belt sander this weekend, and I had ordered one extra socket because I knew I'd find a home for it, so we'll see where that one winds up.  Thanks again!
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline SRSemenza

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  • Finger Lakes Region, NY State , USA
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #14 on: October 29, 2013, 09:52 PM »
You might want to mark the cords that the lug  has been removed from so that you don't mix them up.


Seth

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #15 on: October 29, 2013, 10:17 PM »
Thought of that as soon as I read the previous reply./Users/slugbutter/Pictures/iPhoto Library/Previews/2013/10/29/20131029-221448/XMKdYCeSStSYcxRMffDMDA/IMG_1201.jpg
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #16 on: October 29, 2013, 10:17 PM »
[ Attachment Invalid Or Does Not Exist ] /Users/slugbutter/Pictures/iPhoto Library/Previews/2013/10/29/20131029-221448/XMKdYCeSStSYcxRMffDMDA/IMG_1201.jpg
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #17 on: October 29, 2013, 10:18 PM »
clearly I am not very good at posting pictures
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline NERemodeling

  • Posts: 608
    • New England Remodeling, LLC
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #18 on: October 29, 2013, 10:41 PM »
clearly I am not very good at posting pictures


Hahaha.  But you tried hard, that's what counts!

In the screen when writing your post, look below the text box where it says additional options...   now where it says attach, select choose file, browse your computer for the pic you want and select it.
Now go to the drop down box above the text box that says "insert inline image" from the list select attach image as full size..

Your done,  now post!!

Let me know if your still having trouble

John
CT26  -  (2) Midi  - Planex - Kapex -  Domino 500  -  Carvex  -  TS55EQ -  Rails; 800, 1080, 1400(holy rail), 1900, 3000 -  OF1400 - OF1010  - LR 32 - RO 150 - RO90 - RAS115 - ETS125 - DTS400 - LS130 -  EHL65 - HL850 -  MFT1080 - (2) MFT800

Offline rjwz28

  • Posts: 190
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #19 on: November 07, 2013, 02:05 AM »
So I got my plug it sockets and had some free time today to hack up my makita track saw.  I had to nip off the tabs on the back of the plug it adapter because the makita cord comes sideways out of a hole that doesn't have a seam in it, but all in all it was a pretty simple project.  One of the wires coming out of the socket was too short, but nothing a little splice couldn't fix.  The only thing I didn't get was that all of the plug it cords i have, as well as all of the festool tools i have, have a triangular notch cut out of the socket, but the plug it socket that I got from festool, which was listed as a replacement part for the ts55, doesn't have that.  As a result I had to cut off the matching notch on one of my plug it cords to fit into the socket I'd just put in the track saw.  Anybody know anything about this?

I just got my socket #491725 (thanks "Mahala Homecraft" for the number) and mine didn't have the notch, so I grinded one with my dremel.  Is it okay to use this socket with a DeWalt track saw?  That's what I was going to use it on like how the OP with his non-Festool tools.

Thankls,
Rob

Offline Joseph C

  • Posts: 266
    • Integrity Design+Build
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #20 on: November 07, 2013, 02:25 AM »
I just got my socket #491725 (thanks "Mahala Homecraft" for the number) and mine didn't have the notch, so I grinded one with my dremel.  Is it okay to use this socket with a DeWalt track saw?  That's what I was going to use it on like how the OP with his non-Festool tools.

Thankls,
Rob


First off, to all viewing this thread, in case it isn't obvious, a hack like this invalidates your warranty, and I personally don't condone or encourage to do the same as I have,  you do so at your own risk.

Second, to Rob, there's no call to make a notch in the plugit socket - you should be using a 16ga cord with a track saw.  Using an 18ga cord (which has the triangular doohicky) to connect to it will supply less than ideal power and may run down your motor prematurely.
TS75, OF1010, PS300, Domino500, MFT/3, CT22 + WCR, CT MIDI, RS2e, RO150, ETS150, DS400, RO90, Grex 2" micropinner (festool green), and packing everything else into systainers, too.

Offline rjwz28

  • Posts: 190
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #21 on: November 07, 2013, 12:56 PM »
I was going a little crazy, ready to order parts from Europe (again), and then I found this thread.  What a great idea, can't believe I didn't think of it myself!  Just ordered a few of the ts55 sockets to install on various tools. 

Part number by the way is 491725, and that's for American 110 V.

Thanks again!


Is this part no. for the heavier 16 gauge wire?  I got this exact one for my DeWalt track saw and want to make sure it is the right one.  It seams like it may not be from the previous post.  Just double checking.

Thanks,
Rob

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #22 on: November 07, 2013, 01:14 PM »
Yes, it is.  This is the socket that comes with the ts55, so it should be sufficient for another track saw.  The issue is not the socket, it's the plug it cord you're using.  The 18 ga cords have that extra triangle so they won't fit into the ts55 socket which lacks the cutout for said triangle.  Using this part, you just need to pair it with the proper 16 ga plug it cord which also lacks the triangle.
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline Corwin

  • Posts: 2644
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #23 on: November 07, 2013, 01:34 PM »
Years back I had the thought of dealing with my non-plugit tools in a different way…  My thought was to run a standard cord down the hose, instead of the plug it cord.  Then you could shorten all corded tools such that their cords were nothing more than pigtails.  Also make up a pigtail for you plugit tools from a 16 gauge plugit cord.  Haven't actually done this, but it may prove easier than trying to install these plugit sockets into your tools.  Just a thought...

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #24 on: November 07, 2013, 02:09 PM »
That seems like a pretty easy option, but it still involves opening up the tools.  I have an electric drill that I use mostly for kreg drilling, and for that I'm getting a short plug it extension, but for keeping one plug it cord velcroed to your vac hose, having the socket installed within the tool will keep things neater and you won't have that extra loop of cord at the end of the hose.  With my drill situation, the hose goes to the jig and the cord goes to the drill, so having some extra cord will actually be handy.
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline rjwz28

  • Posts: 190
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #25 on: November 08, 2013, 02:47 AM »
Yes, it is.  This is the socket that comes with the ts55, so it should be sufficient for another track saw.  The issue is not the socket, it's the plug it cord you're using.  The 18 ga cords have that extra triangle so they won't fit into the ts55 socket which lacks the cutout for said triangle.  Using this part, you just need to pair it with the proper 16 ga plug it cord which also lacks the triangle.

Now I get it.  I didn't realize until now that the different Festool tools use different gauge power cords.  Bummers.  I thought I could make my DeWalt easier to use.

Thanks.

Offline MahalaHomecraft

  • Posts: 146
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #26 on: November 08, 2013, 07:18 AM »
...you can.  You just need to get a 16ga plug it cord to go with the part number I listed for the socket.
Makita track saw, C12, ro 90, ets 125, lr32, of1010, sortainer, surfix, European installer set, Trion ps300, 125 and 90 abrasive systainers, systoolbox, cleaning kit, CT midi, lr32 1400 rail, 2 regular 1400 rails

Offline rjwz28

  • Posts: 190
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #27 on: November 08, 2013, 12:35 PM »
...you can.  You just need to get a 16ga plug it cord to go with the part number I listed for the socket.

Exactly right.  The only thing is I already have the other power cord in the sleeve with the shrink tubing over with the boom and don't want to do it all over again and also buy the other cord when I have 3 cords of the smaller gauge.

Thanks for the info.  Much appreciated.

Rob

Offline DrD

  • Posts: 416
  • I might not be fast BUT I sure am slow
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #28 on: December 21, 2016, 11:26 AM »
@Corwin
Years back I had the thought of dealing with my non-plugit tools in a different way…  My thought was to run a standard cord down the hose, instead of the plug it cord.  Then you could shorten all corded tools such that their cords were nothing more than pigtails.  Also make up a pigtail for you plugit tools from a 16 gauge plugit cord.  Haven't actually done this, but it may prove easier than trying to install these plugit sockets into your tools.  Just a thought...

Have you done this yet?  I am planning on getting rid of the cords attached to my RAS and RS2 - both are now out of warranty.

Thanks
KS12 EB Kapex with Delta Folding Table & FastCap Best Fence; TS75 EQ with Parallel Guide Rail Set (FS-PA 495717 & FS-PA-VL 495718) and FS 800/2, 1080/2, 1400/2 LR32, 1400/2, 1900/2 Guide Rails, and Betterly SLC23 Straight Line Connector; DF500 Q with Assortment Systainer; OF1010 EQ with Fine Adjuster for Guide Stop, WA-OF Angle Arm, UP-OF Edging Plate and SF-OF Chip Deflector (486242); OF1400 EQ with OF1400 Dust Hood x 2, OF 1400  Edge Guide x 2, OF 1400  Guide Stop; LR32 Set; PSB399 EQ; EHL65 E; RAS115.04 E; RS2 E; ETS150/3 EQ; RO150 FEQ; Hand Sanding Block Set; CT26 with assortment of AS and Non-AS Hoses; MFT/3 Table x2; SysLite; Assortment of Quick & Screw Clamps, Consumables, Dogs.

Offline Corwin

  • Posts: 2644
Re: Plug-It SYSTEM HACK! Bringing non-Festools into the fold
« Reply #29 on: December 21, 2016, 01:03 PM »

Have you done this yet?  I am planning on getting rid of the cords attached to my RAS and RS2 - both are now out of warranty.


Nope. I was just using my RS2 yesterday and I just don't find the cord issue bothersome enough to modify the non-plugit tools.