Plug-It SYSTEM HACK! Bringing non-Festools into the fold

[BUTTER]

I've always been supremely frustrated whenever I have to switch from a Festool Plug-It cord to a non-Festool cord.
When scribing, I use a Bosch 1594 planer and a Porter Cable mini-belt sander.  Both connect to my DC hose, but the tangle of plugging/unplugging is a mess!

I had a rare bit of free time this afternoon, and have successfully converted both to the Plug-It system  [thumbs up]

My local dealer stocks the Festool tool end replacement part.  I thought that I might have to do a more extensive modification of the tools with a Dremel, but the process was surprisingly simpler.

I found that the wings of the Festool plug, with just a little modification, fit around the part that holds the tool's cord reinforcement.  I  used epoxy paste to mold the tool casing and Festool plug -  I assembled all together, then disassembled the plug part while the epoxy dried (for future servicing,) then reassembled.  I used insulated butt splices for the connections.  After it was all together I packed a little more epoxy paste between the outside of the tool body and the back of the plug to stiffen things up.

I've seen some other UK/EU members use a NAINA part for this, forming a whip, and I'd love to see what other members have come up with!

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[BUTTER]

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[lino-man]

Nice. I love that little pc sander. It's the perfect size for carrying in the van. I gotta make this mod to mine. Do you have the part number handy?

 

[BUTTER]

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[Guilliaume woodworks]

Wow..that is simple..think I will give it a try! Thanks for the post.

 

[rmwarren]

Joseph, that is awesome! I have, uhhmnnn, "imported" a few of the whips to convert tools but I like your solution much better.

Do you have the part number for the piece you used?

Thanks,

RMW 

 

[NERemodeling]

very cool!   i have been wanting to do this to my HL850 for some time now but didnt want to void the warranty (sept this year)     i just sent it out for a little tune up service and to address a few possible issues before the warranty expires, when i get it back i be doing something similar to this!

i could tell by looking at the HL that i would have to mount the plug it lead mostly outside the tool (like yours) and knew i would have to glue it some way to the tools housing to keep it secure.. looks like your epoxy paste is the perfect fit for the job.. nice detail about separating the housing to let it dry so the tool can be serviced down the road!

thanks for sharing!

John

 

[BUTTER]

As far as the part number, you can look it up on EKAT. I used a TS55 part for the planer, thinking it might be a little heavier duty, but the leads looked to be the same gauge as the lighter part I used for the sander.

As far as the epoxy, I keep a stock of Mohawk on hand because of the colors, but there are a number of these machinable two-part epoxy sticks available. Stay away from JB Weld or anything else that actually contains metal, obviously.

 

[MahalaHomecraft]

I was going a little crazy, ready to order parts from Europe (again), and then I found this thread.  What a great idea, can't believe I didn't think of it myself!  Just ordered a few of the ts55 sockets to install on various tools. 

Part number by the way is 491725, and that's for American 110 V.

Thanks again!

 

[festnoob]

Awesome man thanks

 

[MahalaHomecraft]

So I got my plug it sockets and had some free time today to hack up my makita track saw.  I had to nip off the tabs on the back of the plug it adapter because the makita cord comes sideways out of a hole that doesn't have a seam in it, but all in all it was a pretty simple project.  One of the wires coming out of the socket was too short, but nothing a little splice couldn't fix.  The only thing I didn't get was that all of the plug it cords i have, as well as all of the festool tools i have, have a triangular notch cut out of the socket, but the plug it socket that I got from festool, which was listed as a replacement part for the ts55, doesn't have that.  As a result I had to cut off the matching notch on one of my plug it cords to fit into the socket I'd just put in the track saw.  Anybody know anything about this?

 

[rmwarren]

So I got my plug it sockets and had some free time today to hack up my makita track saw.  I had to nip off the tabs on the back of the plug it adapter because the makita cord comes sideways out of a hole that doesn't have a seam in it, but all in all it was a pretty simple project.  One of the wires coming out of the socket was too short, but nothing a little splice couldn't fix.  The only thing I didn't get was that all of the plug it cords i have, as well as all of the festool tools i have, have a triangular notch cut out of the socket, but the plug it socket that I got from festool, which was listed as a replacement part for the ts55, doesn't have that.  As a result I had to cut off the matching notch on one of my plug it cords to fit into the socket I'd just put in the track saw.  Anybody know anything about this?

There are 2 different plugit cords, one is for tools that draw less power and the conductors are smaller. The TS55 comes with the heavier cord, whereas the RO90 (for example) comes with the lighter cord. If I recall correctly this is the cord with and knotch and a tab, the heavier cord only has the notch.

I would not use this setup until I had checked the power draw on the tool and the required conductors for that amperage!

RMW

 

[rmwarren]

I ran out to the shop to get a couple pictures to clarify this. On the Rockler site they sell both 16 and 18 gauge cords:

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This is the 16 gauge cord that came with my TS55:

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This is the 18 gauge cord that came with my Carvex:

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Basically they designed it so the heavier cord (16 gauge) works with all tools but the 18 gauge cord only fits tools with a lower amp draw.

Hope this helps.

RMW

 

[MahalaHomecraft]

Helps a lot in fact!

All of my festools fit into the lower-draw category for sure, hence the discrepancy.  I'll be sure to pick up an appropriate extra as I like having one per tool anyway.  I'm gonna grab my little PC belt sander this weekend, and I had ordered one extra socket because I knew I'd find a home for it, so we'll see where that one winds up.  Thanks again!

 

[semenza]

You might want to mark the cords that the lug  has been removed from so that you don't mix them up.

Seth

 

[MahalaHomecraft]

Thought of that as soon as I read the previous reply./Users/slugbutter/Pictures/iPhoto Library/Previews/2013/10/29/20131029-221448/XMKdYCeSStSYcxRMffDMDA/IMG_1201.jpg

 

[MahalaHomecraft]

[attachimg=#]/Users/slugbutter/Pictures/iPhoto Library/Previews/2013/10/29/20131029-221448/XMKdYCeSStSYcxRMffDMDA/IMG_1201.jpg

 

[MahalaHomecraft]

clearly I am not very good at posting pictures

 

[NERemodeling]

clearly I am not very good at posting pictures

Hahaha.  But you tried hard, that's what counts!

In the screen when writing your post, look below the text box where it says additional options...  now where it says attach, select choose file, browse your computer for the pic you want and select it.
Now go to the drop down box above the text box that says "insert inline image" from the list select attach image as full size..

Your done,  now post!!

Let me know if your still having trouble

John

 

[rjwz28]

So I got my plug it sockets and had some free time today to hack up my makita track saw.  I had to nip off the tabs on the back of the plug it adapter because the makita cord comes sideways out of a hole that doesn't have a seam in it, but all in all it was a pretty simple project.  One of the wires coming out of the socket was too short, but nothing a little splice couldn't fix.  The only thing I didn't get was that all of the plug it cords i have, as well as all of the festool tools i have, have a triangular notch cut out of the socket, but the plug it socket that I got from festool, which was listed as a replacement part for the ts55, doesn't have that.  As a result I had to cut off the matching notch on one of my plug it cords to fit into the socket I'd just put in the track saw.  Anybody know anything about this?

I just got my socket #491725 (thanks "Mahala Homecraft" for the number) and mine didn't have the notch, so I grinded one with my dremel.  Is it okay to use this socket with a DeWalt track saw?  That's what I was going to use it on like how the OP with his non-Festool tools.

Thankls,
Rob