Ryan's SYS-Stacker Router Bit Storage Insert for T-LOC Systainers

[jdv84usn]

Sounds great, I'm in.

 

[Claimdude]

Ryan,

Will you be making these kits for those of use who don't have access to a CNC locally? I am happy to pay for mine.

Jack

 

[GadgetGuy]

Hi Ryan - sorry that the job did not move forward as planned. 

Any idea when the revised dxf plans may be made available for those who signed up for the original order?  Per my earlier email, I will attempt to move forward with a simplified approach using foam inserts (Kaisan or other rigid foam), but still retaining your base + risers design concepts.  My brother-in-law owns a mechanical/electrical product design engineering company, so I will see if I can enlist his help.

If this fork makes sense, then it could be used to create standardized SYS inserts to store/stack anything (tools, bits, etc,) in a more generalized way by utilizing the common "stacking shell" and simply changing custom foam inserts for whatever needs to be stored.

Regards, Mark

 

[Gregor]

Looking at the pictures, I wonder if one tool change per sheet would be feasible?

The router seems to have two heads, one pass could be with the bits you currently use for the contours - then change them to bits sized according to the (many) holes you need to create. You would just need to split the DXF into two (one for the holes and another for the rest) and leave the vacuum table on while changing the bits so the sheet stays in place.

This should turn the routing operations for the hole pass from countour work into simple and quick position&plunge operations and cut down the total processing time quite a bit. The added overhead for tool change would be only once in the middle of each sheet (1st sheet: contours, change, holes - 2nd: holes, change, contours - rinse&repeat), so it shouldn't be that bad, and would remove quite some strain from the bits used for routing the contours.

 

[Claimdude]

Ryan,

I preordered and you refunded but I would be happy to pay $40 for the set of drawings. I have a guy in Shreveport that has made a few MFT tops for me I may be able to get him to do a set for me. Let me know when you are ready for the money.

Thanks
Jack

 

[Bob D.]

Ryan,

I preordered and you refunded but I would be happy to pay $40 for the set of drawings. I have a guy in Shreveport that has made a few MFT tops for me I may be able to get him to do a set for me. Let me know when you are ready for the money.

Thanks
Jack

Ditto, I will find someone locally to run this for me on their CNC. I got my refund but I think the $40 for the drawings and your development time is well worth the asking price.

 

[Magpal]

Awesome project! Very well executed drawings and design! Sorry to see the production being too complicated, as this router bit storage would be very nice to have. Your second solution with the possibility for purchasing the drawings would however also be very interesting.

I do have a couple of questions:
-Do the 8mm bits fit this insert or would you have to make an additional "metric" version?
-I guess 6mm and 12mm bits would fit the 1/4" and 1/2" holes anyway, but if possible I think a pure metric version would be very interesting.
-Will the "top deck" with additional storage rooms fit a SYS-1 alone? I do not have a lot of bits, and it would also be very handy to have some additional room for storing extra bearings etc. A deck with both storage rooms (like on the top deck) and router bit storage would be perfect for weekend warriors like me. Another solution could be to add a couple of "holders"/slots for the red/yellow SYS-1 boxes like Festool has done on the SYS-II drill insert.
-An additional deck for the T-loc sortainer could be very nice. This would be awesome in the bottom drawer of a SYS-combi.
-A "foam friendly" version in a single layer would also be interesting, as this could be lighter and more cost-effective.

Again, great work! I will probably also be interested in buying the drawings for local CNC manufacturing.

 

[UncleJoe]

Has anyone taken this to a local CNC shop and what were the costs?

 

[ryanjg117]

I've updated the original post in this thread given the evolution of this project into a digital deliverable. Please see the original post if you're interested in purchasing the Fusion 360 CAD/CAM files. Thanks.

 

[sylthecru]

Ryan,

Is the plans still available?

Introducing Ryan’s SYS-Stacker Inserts: Router Bit Storage
Now a "Digital" Project

Production Update: Many of you have been following the evolution of this project -- thanks for the interest! After attempting to perform the CNC work myself (140+ decks), I quickly realized that I had "bit off a little more than I could chew." So, I've switched gears and instead have made the Fusion 360 CAD/CAM files available for purchase. With access to these files, you can go to any good, local CNC shop and have them cut your kit in anywhere from 20 minutes (for a basic SYS1 kit) to approximately 100 minutes (for a SYS4 kit). I've also included assembly instructions in a standalone PDF. If you're interested in the design files, I'm asking $40 USD for those who didn't put in an original pre-order; for those who were generous enough to put in a pre-order, I'm asking for $25 USD. Just PM me if you'd like to purchase.

Here, a SYS3 kit is depicted. This new design uses two 9mm platforms for the top and bottom, light but very strong.

This new design retains the stepped hole functionality, so you can place 1/2" or 1/4" shank bits. New dogbone design helps to self-center the platforms for assembly.

Decks retain stackability, with a simpler design that uses only two risers (plus the handle).

Here's an example of the nested Fusion 360 file for the SYS4 kit, which is cut from a single 53x27" sheet. All toolpaths have been fully defined -- just bring your 1/4" down-cut spiral bit!

So, what makes these inserts so cool?

• Mix and match to fit your specific T-LOC Systainer, from SYS1 to SYS4: two deck configurations, and three different “riser kits.” (For optimal configurations to fit your Systainer, see bottom of post.)
• A dual-shank hole design means you can insert your 1/2" and 1/4" router bits into the same hole!
• Each deck is stackable, making it easy to quickly access your bits, no matter how far down you put them.
• Each deck is made from two layers of 9mm thick Baltic birch plywood, offering plenty of rigidity while also saving on weight.
• Incredible capacity: closed decks hold more than 127 bits, and open decks hold 68 bits--limited only by the cutting diameter of your bits.
• Cut with CNC precision, so every piece fits perfectly.

Let's discuss the decks: open or closed?

A closed deck is best for maximizing the router bit capacity, is ideal for smaller Systainers (SYS 1 and SYS2), and also works well as a lower or bottom deck on larger Systainers (SYS3 and up). The open deck serves as a perfect top-level for larger Systainers, and with this open design, you can store particularly tall bits in this area without having to worry about headroom.

What kit is best for my particular Systainer? See below for my recommended kit, guaranteed to fit. (Note that I have not tested fitment on Systainer Classics; just the T-LOCs.)

The below renderings depict my previous design that utilized 30mm thick baltic birch -- the new design is functionally equivalent (save for slightly less holes), and a lot lighter.

SYS 1 T-LOC Systainer – Recommended Configuration

Closed deck, small handle, plugs instead of risers. This configuration will accommodate router bits ranging from 70 to 80 mm in total length.

SYS 2 T-LOC Systainer – Recommended Configuration

Closed deck, large handle, plugs instead of risers. This configuration will accommodate router bits ranging from 120 to 130 mm in total length. If you’ve got a router bit longer than that, I’d love to see it.

SYS 3 T-LOC Systainer – Recommended Configuration

The preferred Systainer for this insert. One closed deck with medium handle and risers, one open deck with small handle and plugs instead of risers. This configuration will accommodate router bits ranging from 68 to 96 mm in total length, and the “open area” will accommodate bits larger than that.

SYS 4 T-LOC Systainer – Recommended Configuration

Two closed decks with medium handle and risers, one open deck with small handle and plugs instead of risers. This configuration will accommodate router bits up to 96 mm long under the covered portions, and any bits longer than that can be stored in the open area.

 

[mkasdin]

Have you considered kaizen foam to hold the router bits? Much easier and faster to fabricate on a cnc then mdf. Or a hybrid with some 3/8 Baltic birch.

 

[w66der]

Hi Ryan

Are the files still  available

Thanks