Custom Kaizen Foam Project-Fitting a DF 700 XL + Accessories In A Sys 3 M 187

[edwarmr]

Here are some pics of a fun little project I did. I love using Kaizen foam and I recently got some of the black and green foam FastCap released. I’m all about compact storage and the huge Sys 5 case for my Domino XL was driving me crazy. It just takes up too much space. I managed to store it in less than half the space. Two Sys 3 M 187s stacked on top of each other are still shorter than a Sys 5 T-Loc.

Having my Domino XL in a Sys 3 M 187 means I can carry it close to my body using the new side handle (people can hate on these new Systainers all they want but to each his own, I love them [tongue]). It’s super convenient.

Two minor modifications I made to my Domino XL (These two changes allow the Domino XL enough space in the Sys 3 M 187 for the lid to close and everything to be secure):

1.) I replaced the height adjustment M6 screw with a thumb screw with a thinner head (The head of the new thumbscrew is roughly 1/2” in diameter and 3/8” in height. The threaded part of the thumb screw needs to be about 3/4” long. I’m sure cheaper thumbscrews can be found but here is the one I bought:https://www.amazon.com/gp/product/B005RTD2LS/ref=ppx_yo_dt_b_asin_title_o03_s00?ie=UTF8&psc=1)

2.) I replaced the M5 ratchet lever for the angle adjustment with a shorter one (I got the knob from China as it was hard to find a US supplier. An M5 wing nut works as well if you grind the wings down height wise a bit. A regular thumb screw will not give you enough force to lock the angle adjustment down securely. You need leverage from a wing nut or ratchet lever nut. A thumbscrew does however work for the height adjustment screw.)

Notice that you can store ALL the Domino XL accessories and cutters plus the DF 500 cutters and leave the Seneca Domi Shim attached to your Domino using this insert. I don’t store plug it cords in my custom inserts; I store them with my hoses since they are always used in conjunction with my CT Mini.

With this setup I can have all my Domino accessories in one Systainer and all my dominos in another Systainer and it is still smaller than the original Domino XL Systainer.

I hope this idea helps anyone else who wants to do this

Here are the pictures:

[attachimg=1][attachimg=2][attachimg=3][attachimg=4][attachurl=5][attachimg=5][attachimg=6]

 

[flair woodworks]

Nice modifications and custom Systainer insert!

 

[Sbradley0911]

Looks nice.  Just did my first foam insert for my shaper origin and workstation stuff.. not finished, I still need to cut a few pockets for smaller bits.
[attachimg=1]

 

[edwarmr]

Nice modifications and custom Systainer insert!

Thanks Chris!

Looks nice.  Just did my first foam insert for my shaper origin and workstation stuff.. not finished, I still need to cut a few pockets for smaller bits.

Thanks! Your insert looks awesome! Did you make the insert using your Shaper Origin? Man I wish I had a CNC or Shaper to make my insert more clean and accurate.

 

[Sbradley0911]

Thanks!  Yeah it was my first go at foam with Origin.  Turned out pretty good minus a few things.  Yeah Origin is a great tool to have but coming from absolutely no CAD experience, there's definitely a learning curve. The on tool CAD is pretty simple but designing something from scratch in software is a whole new beast ..

 

[edwarmr]

I wouldn’t even know where to begin designing my DF 700 insert in CAD. Is there anything reasonably priced out there to scan a tool and then subtract its dimensions from the shape of the insert?

 

[Sbradley0911]

Not that I know of but I don't know that much about the various types of programs out there.  What I do know is that if your a student you can get Fusion 360 for free. That's what I use and have been doing there mastery course on the Autodesk website.  So you could do the same. There's a couple other programs out there like inkscape and Adobe illustrator that people use but I'm unsure of the cost.  Origin needs cut files to be in .svg format so  I'd guess it wouldn't matter what design software you use as long as you can convert and export the. Svg format needed for origin

 

[edwarmr]

I have the free version of Shap3r on my ipad that I’ve been wanting to learn how to use with my Apple pencil. Seems very useful but I think it will have a steep learning curve.

 

[Sbradley0911]

Unfortunately don't know anything about it and I'm not a Mac guy.  Like I said before if your that interested you can get fusion for free and figure it out  through the video tutorials on the autodesk site

 

[edwarmr]

Yeah that’s a good idea, thanks!

 

[Bob D.]

What bit is used for cutting the foam. Is it something other than a carbide bit used for wood. Does one speed work better than another depending on the type of cut. I don't see any signs of serious tearout, or any for that matter, so just curious how you achieved such clean cuts with the Shaper.

It might be possible to use the extrusion tool in SketchUp or other software to create the negative space to cradle the tool.

 

[Cheese]

Another option for learning Fushion is to take a Udemy course. That's what I started to do but I need to get back to it.  [sad]
https://www.udemy.com/courses/search/?q=fusıon&src=sac&kw=fushion

Both of you guys did a nice job on your Systainer inserts.  [smile]

 

[dltflt]

I have the free version of Shap3r on my ipad that I’ve been wanting to learn how to use with my Apple pencil. Seems very useful but I think it will have a steep learning curve.

I just downloaded Shaper3d but I can’t find my pencil.

 

[Sbradley0911]

Thanks for the compliments,  used a standard 1/4" 2 flute upspiral on speed 4 (19,600 rpm) on the origin.  There really wasn't much fuzz with the foam but the trick is hitting it with a heat gun afterwards and that really makes it look like it was factory made. 

 

[edwarmr]

Another option for learning Fushion is to take a Udemy course. That's what I started to do but I need to get back to it.  [sad]
https://www.udemy.com/courses/search/?q=fusıon&src=sac&kw=fushion

Both of you guys did a nice job on your Systainer inserts.  [smile]

I know there are some good videos on Shapr3D online. I just need to take the time to practice.
Thanks for the kind words! [member=44099]Cheese[/member] , I just made an insert for the sanding edge guide with my RTSC 400, charger, batteries, dust bag, sandpaper, and extra base that fits in a Sys 3 M 187. It’s pretty cool. I know you posted about storing it in a Sys 2. I’ll make a post with some pictures tomorrow

 

[Cheese]

I just made an insert for the sanding edge guide with my RTSC 400, charger, batteries, dust bag, sandpaper, and extra base that fits in a Sys 3 M 187. It’s pretty cool. I know you posted about storing it in a Sys 2. I’ll make a post with some pictures tomorrow

I’m interested in seeing your design, your usual execution is pretty nice.  [smile]

 

[Sbradley0911]

[member=44099]Cheese[/member] I've never seen that site for the tutorials before.  The course on Autodesk is pretty good.  They start at the very beginning.. literally starts with opening, saving files and file transfer for the course.  It wasn't terribly hard and you can go at your own pace with pausing the videos.  In not finished by any means but I have the basics down.  One thing thats nice doing it through the autodesk course is that jumping back and forth between a video and fusion is easy since it's all the same program and there's shortcuts in the fusion Taskbar for course progress and navigation

 

[edwarmr]

I just made an insert for the sanding edge guide with my RTSC 400, charger, batteries, dust bag, sandpaper, and extra base that fits in a Sys 3 M 187. It’s pretty cool. I know you posted about storing it in a Sys 2. Ill make a post with some pictures tomorrow

I’m interested in seeing your design, your usual execution is pretty nice.  [smile]

Thanks [member=44099]Cheese[/member] !
I just made a post with the new insert here:https://www.festoolownersgroup.com/...-a-sys-3-m-187/msg630311/?topicseen#msg630311