Finally built my own Sysports.

Imemiter said:
What's in the mystery Sys3? Immdying here!  [smile]
Click to expand...

Nothing yet! Bought it for some random stuff, but I am thinking it might get all of my clamps, etc. related to pocket hole stuff.
 
What are the dimensions of cabinets? I’ve been looking to build a couple, but I’m struggling to find accurate dimensions.

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Mine are loosely built after the pattern that the guy from the WoodGrafter (Youtube). He built them based on the "unit" scale of the T-locs, so that they would always fit with the right combination. Eric from the Poplar Shop (Youtube) did them about the same. Mine are not on wheels though, so I guess it's not exactly "ports" if it is supposed to mean portable, rather than docking station.
I'm thinking that it's about time for a new one though, I just got a TS75 with no place to go.
 

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Looks like the Festool shelves/pullouts make the DIY SYSport a lot easier to build.
 
Those are very nice. 

I started off building mine with plywood "drawers" and full extension slides, after building a few the SYS-AZ came out and I switched to those for the rest of the Sysports.  For me it is not worth re-doing the existing ones, they work fine, but I like the SYS-AZ ones better - they are a bit lighter if I ever need to life them and can fit more in the same height cabinet, especially SYS-1 and SYS-2 heights.
 
Jason Hagen said:
What are the dimensions of cabinets? I’ve been looking to build a couple, but I’m struggling to find accurate dimensions.

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Click to expand...

Here are my cutlists: [attachimg=1]

I made them a little smaller than "real sysports so that I could get two full units out of one 4x8 sheet of plywood, but after I made two, I realized I could make them slightly taller so that I could get more "slots" out of each one... These ones give me 29 "slots" according to SYS-AZ documentation. Worked out almost perfectly, so I'm not too bothered by it. I was using Festool's (MAX 1m) dimensions while making them. I assembled these with 8 pocket screws in the top and bottom pieces, and 4 in each stretcher, in case you were wondering why the top is assembled "between" the sides instead of the other way around. The painted tops are MDF cut to the same size as the top/bottom pieces, but I cut mating dominos into the right side of each to secure them, but did not glue them in or anything. Just keeps them from moving around. Casters were some decent-duty ones I have used from amazon on all my shop equipment.
I used the LR-32 and my 1040 router on the track to drill the holes in True32 fashion, so the SysAZs worked out properly.

Pro-tip: when counting holes from the top front-left, the top counts as one hole, so if your top takes 4 holes per the documentation, you'll go three holes down from the top for the track, put the lock tab on the fourth hole, and then from there, count down in the front-left starting at the lock tab hole on the left, and from the first hole under the track on the right / rears. I attached a snippet of the SYS AZ documentation for how to dimension the holes using the LR-32 The rear as a little extra room, and the LR-32 will need to be used in its alternate mode to set the parallel stops just right, but it's not too hard to do the math and check with a scribe line at the top and bottom of the first piece you do... Just drill out all the fronts first, then move on to the rears. I also cut extra stretchers to fill in the bottom "gap" under the first drawer. Just a visual thing, and gave the screws on the casters a little extra to "bite"

[attachimg=2]

I'm also attaching a ZIP file with an excel spreadsheet you can use to copy / paste from the "menu of options" into the "empty sysports." This will calculate how everything will fit given the dimensions of these (though if you build with more / less "slots" it'll work for that calculation too). Hope this helps!!!

[attachurl=3]
 

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Nice.  What size casters did you go with there?  I've been fuzzing about trying to find one that doesn't swivel into an unbalanced center of gravity without hitting the neighbors and still supporting some weight.  Thanks in advance.
 
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