Kapex / Sysport / MFT?

[badtastex]

I really like the idea of a sysport with an angle towards Kapex/general miter saw and I am in the process of designing one for myself.

Did you design the depth based on the dust collector or is there some other thought behind it? How much depth do you think the kapex would need (I still do not own one...)?
For my design I am going with something a litte bit shallower (~500mm) that will fit perfectly on one of my walls and I will go for an adjustable shelf in the middle or slightly off-center for the saw itself.

Looks good!

 

[Carl Prentiss]

Good on you Shed for doing your own thing and sharing the results. It would be boring if everyone built to the same design. I'm afraid some of my projects would be declared a waste of material.

 

[shed9]

I really like the idea of a sysport with an angle towards Kapex/general miter saw and I am in the process of designing one for myself.

Did you design the depth based on the dust collector or is there some other thought behind it? How much depth do you think the kapex would need (I still do not own one...)?
For my design I am going with something a litte bit shallower (~500mm) that will fit perfectly on one of my walls and I will go for an adjustable shelf in the middle or slightly off-center for the saw itself.

Looks good!

Hi badtastex, the depth on my unit was biased towards a useable top surface. The Kapex needs about 600mm from the back of the cable tidy to the front of the arc of the cast base and the width is about the same (I think it measures about 615mm left to right). If you built a surface that was 500mm directly from the wall the Kapex will overhang and require additional support for the mounting holes if that makes sense. You could build a 500mm surface and just have minimum support for the saw supports. I'll get the correct measurements in the morning and post them up if that helps.

Good on you Shed for doing your own thing and sharing the results. It would be boring if everyone built to the same design. I'm afraid some of my projects would be declared a waste of material.

Cheers for the comments Charlie Mac, and that birdhouse will polish right out  [unsure]

 

[Kev]

Good on you Shed for doing your own thing and sharing the results. It would be boring if everyone built to the same design. I'm afraid some of my projects would be declared a waste of material.

I suppose you need to look at it from a bird's perspective [huh]

 

[Samo]

Hey Guys,   [smile]

This is a project I want to do also.

My ideas are not new, just must haves for me.

Welded steel base - angle, channel, whatever.  Including locking casters and levelers with channels for a pallet jack or forklift.

Back panel -  Panels for hanging things.  Things like tool accessories, notes, pinup girls and whatever.  Peg board or slat wall?

Back panel also around Kapex.  Integrated with some dust collection for additional help when available (besides a CT under saw) and/or a chip/cut off bucket or bin built in.

MFT style ext. tables.  Could be possibly be torsion box construction with access areas along the sides for quick tool storage - Paulk style?  Good fence and flip stops of coarse.

Another benefit for me personally, being so accident prone, with the panel behind and around the Kapex- if something falls over on it, maybe it could save the day.

These are just a couple of things to add to the great build going on above.  Definitely need the weight savings and flexibility that the 8020 gives us for changes in a prototype design....

Pin up girls are obviously my wife and daughter.  Thx, Sam

 

[mattfc]

Welded steel base - angle, channel, whatever.  Including locking casters and levelers with channels for a pallet jack or forklift.

Back panel -  Panels for hanging things.  Things like tool accessories, notes, pinup girls and whatever.  Peg board or slat wall?

My build using profile covered a couple of these points (I did a KAPEX sysport and an MFT/CMS sysport)
http://festoolownersgroup.com/festool-jigs-tool-enhancements/sysport-cms-mft-(work-in-progress)/msg157691/#msg157691

 

[shed9]

okay, update on this one. I'd recently double checked ideas for wings on a recent thread re: crown extensions or UG wings or just use the table. Anyhow I went for a solution which is half way between. I reworked the top to drop down the saw and fitted a pair of crown extensions. I also added some 40x120 extrusion either side of the saw as a full scale fence and this works really well.

I had to change the usual Festool knobs under the crown extensions as they stuck out beyond the profile of the edge but other than that it fits perfectly. I've cut either side of the tops to size and given a quick going over with wax to help retain the edges when I machine them down. I'm going to fit T-track for the fence and drill MFT style holes to achieve other clamping options (elements, etc) when cutting and also with the fences removed I effectively end up with another two MFT style surfaces.

As a side note, it turns out the new Sys-az drawers will fit perfectly in this so may try this route.

I still need to fit the inter sections of the aluminium, finish the tops and machine a mid top section. Any advice welcome  [smile]

 

[Kevin Stricker]

This solution is looking pretty nice.  You are going to have some problems with your current fence setup unfortunately. With any bevel cuts and some miter cuts you need to be able to slide and or remove your Kapex fence.  This requires about 4" of clearance on each side.  Two options are to a) slide extrusions to the side so the fence can clear or b) set the extrusions back so that the fence can clear. 

Although it is counter-intuitive, having your extension fence line up with your Kapex fence is actually not such a great idea.  Any bow in your stock will keep you from getting a square reference off your fence and thus an up square crosscut.  So I would set back your extrusions enough that your Kapex fence can slide out, and just make sure your stop can reach. 

As for the Sysport drawers, don't wait a year for Festool to release it's new drawers in the states.  It's very easy to make your own, you don't even need drawer boxes.  Screw the drawer glides to 3/4" BB plywood, add a front lip/catch and a square block screwed into the back sized for a Systainer.  Guedo Henn has a great video in his Chaos theory series on this simple and attractive option. Good luck.

 

[shed9]

This solution is looking pretty nice.  You are going to have some problems with your current fence setup unfortunately. With any bevel cuts and some miter cuts you need to be able to slide and or remove your Kapex fence.  This requires about 4" of clearance on each side.  Two options are to a) slide extrusions to the side so the fence can clear or b) set the extrusions back so that the fence can clear. 

Although it is counter-intuitive, having your extension fence line up with your Kapex fence is actually not such a great idea.  Any bow in your stock will keep you from getting a square reference off your fence and thus an up square crosscut.  So I would set back your extrusions enough that your Kapex fence can slide out, and just make sure your stop can reach. 

As for the Sysport drawers, don't wait a year for Festool to release it's new drawers in the states.  It's very easy to make your own, you don't even need drawer boxes.  Screw the drawer glides to 3/4" BB plywood, add a front lip/catch and a square block screwed into the back sized for a Systainer.  Guedo Henn has a great video in his Chaos theory series on this simple and attractive option. Good luck.

Hi Kevin, appreciate the comments but already ahead of you.

The fence is only sat on the surface for now, I’m going to fit T-tracks and the fence will move out of the way either side and front to back so not a problem in the bevel cuts. One of the reasons I’ve fitted crown extensions is to enable that ability to cut compound bevel in situ without issue.
Also any wood that makes it on this bench will already be true so no need to move the fence – besides that would kind of defeat the point of having a fence if it is set back.

As for the Sys-az drawers, I’m in the UK so should be available in the next few weeks if not already. That said, I’ve spaced the unit rows to allow for five standard Systainers and one Midi Systainer drawer unit. As the Sys-az’s are standard this may end up in a custom job anyhow.

EDIT: Just read up on Guedo Henn, never heard of him before - loads of cool info, thanks for the heads up on that one.

 

[shed9]

Well overdue update on this one, been stupidly busy but managed to get some free time and got a few things ordered to finish this off. Just delivered  [smile]

Firstly a dedicated Midi to fit under the saw;



And an initial order of Sys-AZ's, fifteen for starters to go in the bench;



Also ordered a few extra lengths of extrusion to fit in another line of drawers; the original idea was to fit ply or MDF boards with standard drawer runners and fit multiple widths with a single Midi-Systainer width space however this is now moot and anyway the Sys-AZ's don't come in Midi width yet (hint-hint Festool) so I'm fitting another upright for more drawers. I'll use the small space left for a pull out board to mount blades and accessories (if that makes sense).

Anywho - will finally get my Systainers in some form of order - watch this space.

 

[shed9]

Dang, the cost so far just boggles the mind. Good for you though, I'm sure you'll enjoy it.

Thanks Cochese but to be honest it's not cost that much at all especially when put into the context of Festool kit. The alloy for the bench and the drawers set against an UG stand with wings and three or more Sysports would far exceed the budget so far. And a dedicated Midi is a given for my use of the Kapex in my opinion.

 

[sakurama]

Looks great. This sort of thing is great for showing what's possible. Kudos.

Gregor

 

[KGB pilot125]

I have known about 80/20 for a while, mostly from people building sim racing cockpits from them.  A couple of weeks ago I stumbled on a collapsible work table made from 80/20 and now I see this.  That sure looks sharp OP and I cant wait to see the drawers attached.

If you had to do it over again is there anything that you would have changed?   

 

[Samo]

The 80/20 is great for the " What would you change if you could do it over again? ".

I'm watching this build also as I have been stupid busy with other business and family stuff. 

Shed, The Midi is a great little CT and on my Kapex it has been cycled thousands of times and I'm very satisfied with the bag life.

Cheers, Sam