I just wanted to a do a quick review of the pre-cut Kaizen foam systainer inserts which are available from "BP Way Tools". Here is a link to their Ebay store: BP Way Foam Inserts
I have made my own kaizen inserts before and have a hardboard template that I use to quickly trace out the systainer outline, but this product is compelling because the price is VERY reasonable. It saves probably about 20 minutes of bandsaw work and the result is much more accurate.
A word of caution though. I ordered four of these and when they arrived I was very busy with business travel and also my sons Eagle Scout project. So I took the opened box and set it in the garage just outside the entry door. A couple weeks went by and I decided on Fathers day to try out the inserts. I thought I had put them in the shop, but they were no where to be found. A quick search found the box of pre-cuts sitting in the pile of "to be recycled" cardboard boxes. My wife had seen the box and thought the inserts were simply packing material from something else that I got. Fortunately, they didn't go out in the recycling pickup!
The inserts are accurately cut and my only complaint is that they are just a tad too tight. They could probably be another 1 or 2 mm smaller and still provide a good fit. As is, you are literally scraping off "fuzz" when putting them in the systainer for the first time.
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They are not complete as received. The inserts appear to have been CNC'd from a two dimensional model of the systainer outline and as such they are missing some crucial cutouts which must be made by hand before you can actually use them.
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To be specific, there are four "notches" which must be made on the bottom so that the foam will fit around the indentations where the sustainers stacking/locking mechanism intrude on the interior.
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Here is the insert with the notches made:
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On a Sys 1, you must also notch out for the lid hinge pins.
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Lastly, you will need to cut a slit on the middle front for the reinforcement rib behind the T-Loc latch area.
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Overall, it is a good product and saved me lots of time, didn't cost any more, and provided a good fit. My only critique is that BP Way Tools move to a 3D CAD model and cut the inserts upside down so that the notches could also be cut.
[attachthumb=#]
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I have made my own kaizen inserts before and have a hardboard template that I use to quickly trace out the systainer outline, but this product is compelling because the price is VERY reasonable. It saves probably about 20 minutes of bandsaw work and the result is much more accurate.
A word of caution though. I ordered four of these and when they arrived I was very busy with business travel and also my sons Eagle Scout project. So I took the opened box and set it in the garage just outside the entry door. A couple weeks went by and I decided on Fathers day to try out the inserts. I thought I had put them in the shop, but they were no where to be found. A quick search found the box of pre-cuts sitting in the pile of "to be recycled" cardboard boxes. My wife had seen the box and thought the inserts were simply packing material from something else that I got. Fortunately, they didn't go out in the recycling pickup!
The inserts are accurately cut and my only complaint is that they are just a tad too tight. They could probably be another 1 or 2 mm smaller and still provide a good fit. As is, you are literally scraping off "fuzz" when putting them in the systainer for the first time.
[attachthumb=#]
[attachthumb=#]
They are not complete as received. The inserts appear to have been CNC'd from a two dimensional model of the systainer outline and as such they are missing some crucial cutouts which must be made by hand before you can actually use them.
[attachthumb=#]
To be specific, there are four "notches" which must be made on the bottom so that the foam will fit around the indentations where the sustainers stacking/locking mechanism intrude on the interior.
[attachthumb=#]
Here is the insert with the notches made:
[attachthumb=#]
On a Sys 1, you must also notch out for the lid hinge pins.
[attachthumb=#]
Lastly, you will need to cut a slit on the middle front for the reinforcement rib behind the T-Loc latch area.
[attachthumb=#]
Overall, it is a good product and saved me lots of time, didn't cost any more, and provided a good fit. My only critique is that BP Way Tools move to a 3D CAD model and cut the inserts upside down so that the notches could also be cut.
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