Festool Systainer adjustable storage system.

[karlfife]

I though I'd share my project for storing my Systainers.

This design attempts to maintain space efficiency, while allowing any box to be removed/replaced in the middle of the stack.  Festool offers a steel-frame solution which is half the height/capacity for $650 plus tax/shipping.  I also could have built something out of 80/20 aluminum extrusions, but that would have been surprisingly expensive, and it would have involved putting together a materials list of obscure parts, fasteners, joints etc.

In this solution the boxes rest on inexpensive 3/4 aluminum angle (1/16" thick).  The angle is recessed flush into shallow dadoes in the case. The aluminum angle has been prepped to accept 3 screws which hold it in the dado, but the dado bears all of the weight.

The spacing of the dadoes is slightly greater than the smallest increment in tool box size.   This allows the 'shelves' to be re-arranged to hold any combination of Systainers in any order.

The Walnut edging on the front of the case was ripped from some twisted/warped/bowed 3/4" walnut stock.  It would have otherwise become firewood, but it's easy to make it lie down when cut into strips .  Of note: The wood is from the estate of the inventor of the BelTone hearing aid.

Each dado was cut to width in 2 passes using a guide rail and a router.  Both sides of the case were cut in the same pass.

I had originally planned to put a piece across the middle "shelf" to prevent the case from bowing, but so far it doesn't seem necessary. Maybe because of the shallow depth.

-Karl

 

[jlyons]

I love it. 

 

[harry_mc]

Excellent!  Simple, yet a great use of space.  Thanks for sharing!  ;D

 

[nclemmons]

Nice, simple approach

So what is the uniform distance that you are spacing the dados?  I assume looking at the photos that there is ONE consistent spacing between each aluminum angle dado, yet looking at the photo, it appears that there is some variability on spacing between the various size sustainers.  Just wondering if that is the case?

Would love to see overall dimensions of the cabinet width, height, depth, etc.

Also

 

[karlfife]

I assume looking at the photos that there is ONE consistent spacing between each aluminum angle dado, yet looking at the photo, it appears that there is some variability on spacing between the various size sustainers.

Good question. The dado spacing is uniform/consistent.  The apparent variability is an accidental characteristic of the approach.  

Even though SYS 5 and four SYS 1's stack the same height, putting them in a rack like this requires you to allow space for not only the shelf/support system, but also a little bit of space to allow passage of the systainer, especially since they 'nest' to some degree when just stacked together.  

To make a SYS1 fit between two pieces of aluminum angle on the side of the case, the spacing needs to be the maximum dimension of the Systainer, PLUS some margin to account for the 1/16 thickness of the angle, plus a little bit so you can actually pass the systainer in and out.

What was my spacing?  I took the measurement above and cut it in half.  I'll call that measurement one 'rack unit', or simply "1U"

The SYS 1 takes up 2U.  Per the definition of 2U above, a SYS 1 has "precisely" enough room to fit.  A SYS 2 by contrast takes up 3U.  This results in a slightly more comfortable fit, because the third rack unit brings with it an extra (unneeded) bit of margin.  A SYS 3 takes up 4U, so it actually ends up with DOUBLE the required margin.  With that much extra margin you begin to see variations in the gaps between the systainers. SYS 4 is more noticable.  It's a very slight space inefficiency, and it serves the greater design priority of being able to re-arrange systainers in any combination (because there's enough space for 3 of SYS 1's where the SYS 3 now sits ).  More importantly, it serves to allow me to upgrade and acquire more tools without needing to re-tool my storage system.  

Most recently I sold my T-15 drill for a C-15.  The former came with a SYS2, the latter with a SYS1.  No problemo.

Dimensions:
I'll modify this post to include the ACTUAL measurements when I get back.  The main idea is that even the TOP of the cabinet lands right on the boundary of a rack unit.  You could put a SYS1 on the tippy-top dado/shelf, and it would be a "precise" fit as defined. The width measurement is obvious.  The depth measurement was chosen to leave just enough Systainer sticking proud of the edge banding to allow me to grasp the box comfortably.  After all, there's not enough space to get your fingers between two SYS1's in the rack.  

I hope this helps.