Custom router bit storage insert for SYS4 Systainer

[ryanjg117]

Anyone who has a respectable router bit collection knows that Festool’s 497695 Router Bit Storage Systainer is a joke. Maybe it’s good for storing a few bits “for the road,” but its inability to accommodate tall bits, plus an overall lack of holes for half-inch shank bits make it pretty near useless for me.

I recently happened about a “lot” of about 50 router bits—all high quality carbide bits from Amana, Freud and Whiteside. Many of you know I’ve been modeling Systainers in CAD and have now moved to building custom inserts for them—and here’s my latest rendition:

This custom insert fits inside of a SYS4 Systainer. Each “deck” floats on the side and center supports, so a single deck can be removed independently. I’ve even incorporated some finger-spacing around the edges of each floating deck, to allow the topmost deck to be removed while the entire assembly remains inside the Systainer.

By my count, this insert holds a whopping 279 router bits! That’s 215 half-inch shank bits, and 64 quarter-inch shank bits. Better yet, the decks are tiered such that the lower platform provides 70 mm of “headspace” for taller bits. And for the super-tall bits, a portion of the top deck is open, providing storage space and accessibility for even longer bits. This, combined with the 30 mm extruded holes throughout, make it possible to store a large number of long bits—up to four-inches and longer. The only limitation is their profile girth/diameter, really.

This insert is primary built out of 12 mm Baltic Birch plywood. I’ve incorporated a storage caddie on the top deck, for random pieces we tend to accumulate (bearings, cleaning solution, collets and adapters).

I’m having this machined over the weekend, and will post pictures when fully assembled. If you have any ideas for design improvements, or if you’d like one yourself, let me know.

Ryan

P.S. I've already caught one design flaw: the side-grips are too close to the inner walls of the Systainer. Oh well, I don't have the wherewithal to redesign it now, and I think I'll be using the center grip most often.

 

[Bhend18]

How much would you be selling them for?

 

[McNally Family]

Nice job!

 

[Peter_C]

P.S. I've already caught one design flaw: the side-grips are too close to the inner walls of the Systainer. Oh well, I don't have the wherewithal to redesign it now, and I think I'll be using the center grip most often.

Bring the side grips up higher into the Systainer lid. That way they will be above the side of the Systainer allowing them to be grabbed easier, without a major redesign. I made one of my inserts that way. It actually extends up into the ribs of the Systainer lid.

 

[jdm5]

Interested!

 

[s1301950]

omg... how is anyone going to have a collection that huge to fill that many holes! so far i only have two round bits, and one trim bits.. in their original packaging, thrown around inside the systainer with its router mate.

 

[promark747]

Interested

 

[justaguy]

interested

 

[epicxt]

Interested

 

[Cheese]

I've already caught one design flaw: the side-grips are too close to the inner walls of the Systainer. Oh well, I don't have the wherewithal to redesign it now, and I think I'll be using the center grip most often.

First off...nice job,  [thumbs up]  I especially like the inclusion of the tray sections for bearings & misc screws & hex keys.

So...if the center handle didn't go all the way through the section, but stopped 1/8" below the top surface of the top tier, then you could mount a center handle on the top section and use that to remove the top tier. This same operation could be implemented on the middle tier. Only 1 item needs to be modified, the long center handle/post. Only 2 items need to be designed, the new center handle for the top tier and for the middle tier.

The outside handles would be used to remove the entire structure, while the center handles would remove each tier/layer. The nesting function would be the same as it is now.

Just a thought [popcorn]

 

[VW mick]

Nice

I like that. A sys 4 seems a bit excessive for router bits but I think I'd have a good go at filling it

As my festool sys 1 isn't really up to my collection

But I don't have any room for anything sys 4 sized

Really cool though. Need those spaces for bearings and hex keys etc

Mick

 

[sprior]

I've got an X-Carve CNC and I think an empty Sys1 and Sys4, and have been wondering if maybe some custom inserts might be in my future (don't need router bit storage at the moment, have to come up with something else).  Are there generic outlines available online for the insides of a systainer?  Is the top outline the same as the bottom?

 

[Cheese]

Are there generic outlines available online for the insides of a systainer?  Is the top outline the same as the bottom?

Remember, that these are injection molded boxes that require an internal draft on the walls. So the inside opening at the top of the Systainer will be larger than at the bottom of the Systainer. Also, the larger sized Systainers will have a larger variation in measurements because they are deeper. So, just size your insert to fit at the bottom of the Systainer and you'll be good to go.

 

[sprior]

I was hoping that there is maybe a dxf or svg file around that follows the contours a bit.  I didn't just want to model a rectangle.  Any extra space around the sides just seems like a chance for the insert to rattle around.

 

[tallgrass]

that is a nice design. my only thought is that a couple of hundred router bits will make this heavy. the problem with things that hold " everything" is that you can not lift " everything. "

 

[Svar]

This is beautiful but hardly practical. Pull out drawer is an ergonomic way to organize bits. SYS2 with a simple one layer, easy to see and reach layout for on site use. With the proposed setup every time you need a bit you have to pull out and disassemble the stack.

 

[Cheese]

If you have any ideas for design improvements, or if you’d like one yourself, let me know.

I have the standard Festool router bit storage Systainer and it's just too small. Once you add some tongue & groove bits and some wing slot cutter bits, you run out of room fast.  [sad]

FWIW...my needs would entail needing only 2 tiers. That would reduce the Systainer size and eliminate some of the weight of the ply. To further reduce weight, I'd consider using 4-5mm ply as a base for each tier and then bond some foam to each ply base to support the router bits. There would be a substantial savings in weight.  [big grin]

 

[ryanjg117]

How much would you be selling them for?

How much are you willing to pay?  [wink]

I probably spent about 20+ hours on this design. I'm not really planning on selling them en masse unless I see a lot of interest. But I also need to test the current design and I'm sure I'll have some ideas for improvements.

Bring the side grips up higher into the Systainer lid. That way they will be above the side of the Systainer allowing them to be grabbed easier, without a major redesign. I made one of my inserts that way. It actually extends up into the ribs of the Systainer lid.

According to my SYS4 systainer model accurate down to ~1mm, the Festool lids only have about 12mm of additional headroom, which varies quite a bit due to the wild plastic ribbing around the perimeter, plus the large recess for the handle. After I get it machined and test it out, we'll see if I can pull them up any higher. Likely I'll be able to move them a smidge higher, but pulling them more inside is probably going to be the route I'll eventually take.

omg... how is anyone going to have a collection that huge to fill that many holes! so far i only have two round bits, and one trim bits.. in their original packaging, thrown around inside the systainer with its router mate.

Once you get a router table, things change. I built my own Incra table and it's the most versatile tool in my shop, and probably the most accurate to boot. Sure, you'll probably never be able to fill up this entire insert, but in reality, you won't be able to fill all of these slots anyway, since many bits have large profiles that will take up multiple slots.

So...if the center handle didn't go all the way through the section, but stopped 1/8" below the top surface of the top tier, then you could mount a center handle on the top section and use that to remove the top tier. This same operation could be implemented on the middle tier. Only 1 item needs to be modified, the long center handle/post. Only 2 items need to be designed, the new center handle for the top tier and for the middle tier. The outside handles would be used to remove the entire structure, while the center handles would remove each tier/layer. The nesting function would be the same as it is now. Just a thought [popcorn]

I like your general idea. Having each tier be stackable such that people could use SYS2 through SYS5 would increase the versatility. This might be in store for a future design improvement.

This is beautiful but hardly practical. Pull out drawer is an ergonomic way to organize bits. SYS2 with a simple one layer, easy to see and reach layout for on site use. With the proposed setup every time you need a bit you have to pull out and disassemble the stack.

I agree, it's not a perfect design. Ideally, you would have one extremely large drawer with enough headroom to hold even your longest bits--but that's going to be a very big drawer. I happened to have a couple spare systainers and was hunting for an excuse to fill them, plus I recently acquired a bit lot of router bits. However, I will note that you're free to put your most frequently used bits on the top shelf, and even your most commonly used longer bits could be tucked in the second shelf, but available through the pass-through so that you wouldn't have to remove any tiers. Only your seldom used bits could be stored on the deeper tiers. As an owner of a Freud glass panel router bit set, I know a thing or two about "seldom used bits." I think I'm probably speaking for others with big router bit collections, too.

I was hoping that there is maybe a dxf or svg file around that follows the contours a bit.  I didn't just want to model a rectangle.  Any extra space around the sides just seems like a chance for the insert to rattle around.

There is--do a search for "systainer bottom insert" and you'll find a FOG'er who modeled both the floor and the lid. I used his work to double-check my own here. We'll see if it all fits later this week, when I go to assemble it.

 

[ryanjg117]

All done. Already have a list of about ten enhancements to make with the next version.

Replacing...

 

[flair woodworks]

Your rack looks about 50% full. How much does it weigh?