Domino DF500 Foam Insert

Joined
Sep 30, 2014
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I recently bought a DF500 and the insert in the Systainer was cracked and the paper lid organizer is beat up.  I called Festool and they are going to send me out a new insert.  So after thinking about, and seeing the domino xl and other festool products pack in epp foam, I called a epp foam company and got some prices on getting a foam insert for the df500 and later for more Festool Products. 

So heres my idea;
Epp foam insert for the df500.  It will have the spots for the normal accessories, a spot for the domiplate and a spot for the df500 accessory bit set.  Looking at trying to get it for around $15 plus shipping.  Just checking to see if there is any interest in this upgrade and get a number of people interested before I spend the money on tooling a prototype.  If this works out I would like to do the same for the ts55req and Festool Drills.  Let me know Thanks.
 
would this be like a kaizen foam insert or a laser cut multi color insert?
 
For near that price, I'd be interested in replacing the inserts on all my tools that came with the plastic ones.
 
The issue is tooling cost.  Its only worth while to have them make a batch.  There hasnt been a lot of interest though. 
 
I'm interested.  I think my hesitation is that I can't see a prototype to know if I'd really want one or not.  Not to say they won't be nice but seeing helps sell always.  I rarely buy something that's conceptual because I'm particular.
 
I will meet up with the manufacturer and see about a prototype.    I agree pictures would be will help interest. 
 
OK....I'll ask...... WHY?

What's wrong with the plastic insert that comes with the tool?

I'm not trying to be a D-head.  I'm just trying to understand.   

How are you moving the tool around?  I think the inserts that come with the tools are fine.    Waisted space?  On some.  But I wouldn't pay for an additional insert.

Eric
 
Festool in my opinion dropped the ball when it comes to inserts.  I use my tools for professional use and carry them on and off of job sites.  I bought a new df500 and the insert was broke in multiple spots.  Festool has quality tools and systainers are awesome.  Inserts made of thin brittle plastic is a little dumb.
 
Tyler Ernsberger said:
Festool in my opinion dropped the ball when it comes to inserts.  I use my tools for professional use and carry them on and off of job sites.  I bought a new df500 and the insert was broke in multiple spots.  Festool has quality tools and systainers are awesome.  Inserts made of thin brittle plastic is a little dumb.

Fair enough.  This wouldn't be the first problem with plastic regarding a Festool product.

I'm not a pro.  So I don't move my tools around as much as you.  So I was curious what the problem was with the inserts.

Maybe Kaizen foam or the like,  can help you improve the safety with your tools?   

Eric
 
erock said:
Tyler Ernsberger said:
Festool in my opinion dropped the ball when it comes to inserts.  I use my tools for professional use and carry them on and off of job sites.  I bought a new df500 and the insert was broke in multiple spots.  Festool has quality tools and systainers are awesome.  Inserts made of thin brittle plastic is a little dumb.

Fair enough.  This wouldn't be the first problem with plastic regarding a Festool product.

I'm not a pro.  So I don't move my tools around as much as you.  So I was curious what the problem was with the inserts.

Maybe Kaizen foam or the like,  can help you improve the safety with your tools?   

Eric

I think kaizen foam is a good idea.  I really like the formed epp foam found in the domino xl.  I dont think I want to pay for tooling cost for a prototype In epp foam.  So kaizen may be the best solution.   
 
I wonder about taking the insert out, shooting the back of it with expanding foam sealant, and then placing it on a non-stick surface with the Domino etc in it as ballast, while the foam expands.
If it lifted the insert, you could trim the excess flush after it cured.
I think the key would be not to spray too much- you could always hit it a second time.
It seems like the foam might give the insert the support it needed to not break.

Dave
[scratch chin]
 
Daver said:
I wonder about taking the insert out, shooting the back of it with expanding foam sealant, and then placing it on a non-stick surface with the Domino etc in it as ballast, while the foam expands.
If it lifted the insert, you could trim the excess flush after it cured.
I think the key would be not to spray too much- you could always hit it a second time.
It seems like the foam might give the insert the support it needed to not break.

Dave
[scratch chin]

I have done this before with a Fein insert and it works pretty good,  just use the low expansion for windows and doors. 
 
I had to go look to see which had which of the tools I have.

Plastic
TS 55
DF 500
PS420
DTS 400
RO 150

Foam
DF 700
TS 75
OF 2200

I like the foam much better but honestly, I couldn't have told you which had which without going to look. Being that they live in homemade sysports with soft close slides, it probably doesn't matter much.
 
Problem is cutting the kaizen foam to fit the Systainer and still look good.
 
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