Installing the 3-sided lid insert on a systainer.

Frank Pellow

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Jan 16, 2007
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Last week I purchased this item from Lee Valley (see http://www.leevalley.com/wood/page.aspx?c=1&p=64673&cat=51,64664).  It came with no installation instructions, nor (to my  surprise) were there any on the Lee Valley web site.  I could figure out how to install part of it, but I had no clue how to insert the steel rod into the systainer without (somehow  ???) taking the systainer apart.  This morning, I talked briefly to George in Lee Valley customer service , and his answer is that, indeed, the systainer must be partly taken apart.

In case others are similarly confused, I offer this illustrated tutorial.

1)  Place the systainer so that one of the hinge pins is located over a small hole, such as a dog hole in a woodworking bench.  Insert the rod into the interior of the hinge pin and tap it until it comes out.
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Here is a picture of a partly extracted hinge pin:
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2) Push the rod through loop in the flap then insert it into place:
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But don't do what I did that is don't install it back to front.  :-[

3) Tap the hinge pin onto the rod: [attachthumb=#4]  

4) At this point, I realized that I had inserted the flap the wrong way around on the rod.  So I had to remove the hinge pin again.  I couldn?t use the same technique.  Rather, I pried the pin a little way with some pliers, then used a claw hammer to extract it all the way.
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It's just as well that I figured out this alternative, should I ever want to remove the systainer lid insert some time in the future.

5) The next step is to install the portion that attaches directly to the systainer lid:
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The four holes in the lid attachment must be pressed over the four pins that extrude from the top of the systainer
The attachment snaps easily into place:
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6) Finally, the two screws (shown in the plastic bag in the above photo) are screwed into the two holes in the systainer lid.
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7) Here the lid is installed on a systainer 2 and some of the contents that I intend to store in the systainer have been placed into it.  
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The systainer will be used as my off-site office and will be used to store a netbook computer, a camera, office supplies, my diary, and plans (among other things).

 
Thanks Craig.

You will see that at the end of the tutorial, I said "The systainer will be used as my off-site office and will be used to store a netbook computer, a camera, office supplies, my diary, and plans (among other things).".  After trying this for a little while, I decided that I could make my own lid insert that would do a better job for me.  I describe this in the thread: http://festoolownersgroup.com/festool-jigs-tool-enhancements/a-homemade-'office-top'-that-attaches-to-a-systainer-lid/.  The entire systainer is described in the thread: http://festoolownersgroup.com/festool-jigs-tool-enhancements/a-homemade-'office-top'-that-attaches-to-a-systainer-lid/.

The 3-sided insert is now used in one of the sytainers that I use for miscellaneous tools.
 
Frank,  I've been using the same inserts on a couple of systainers for the better part of a year now.  Never did figure out what the screws were for, so I chucked them into the "junk drawer"  [unsure]  But they do seem to stay in place just fine with just the clips.

All, be careful removing the hinge pins, they are easy to tear up with a claw or any other devise, I know. 

Dan
 
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