Sysport build

[DynaGlide]

Long time lurker here. I'm on round 2 of my sysport build. The first one shown below was made out of imported one side prefinished plywood from China that is so badly warped I can't use it for this purpose. I figured I could force it square with some back panels strategically placed but it's several mm out from one spot to the next. .

Round 2 is using Melamine panels from Lowe's that just happen to be the exact width I designed to accommodate Sys-Az drawers (400mm). The material is 19mm thick and the panels from Lowe's measure actual ~2460mm x 399mm. This allows for a back panel using the same material (19mm) with 380mm left which is exactly the spacing required for a Sys-Az drawer. It's like Tanos designed the drawers to work with this material. This is my first real project with all my cool tools before I move on to doing things that will go inside the house. I still have to finish routing holes, then edgebanding again, then domino and dry fit. On to the pictures:

Setting the 13mm depth for the 5mm holes

Edgebanding

Kreg setup

Version 2 starting over

Really digging the LR32

 

[Dick Mahany]

Great pics and cool project.  Looks like you are having too much fun.  I'm looking forward to progress pics.  It looks like you are getting nice sharp cuts on the melamine.  Which blade are you using?

 

[DynaGlide]

Great pics and cool project.  Looks like you are having too much fun.  I'm looking forward to progress pics.  It looks like you are getting nice sharp cuts on the melamine.  Which blade are you using?

Yes I am. I wish I could just knock it out but I have to do a bit at a time with family and work obligations. I bought the 496309 Solid surface blade before starting the project. I found that using this blade and the splinter guard green plastic doohickey gives nice cuts and eliminates the material sprayout. I forgot to put the green doohickey down on a cut and had a huge mess. I was surprised as I've not used it before.

At the advice of others I'm doing the holes on 16mm centers by repeating with the end stops flipped. The side panels are 1024mm long (divisible by 32. .32 times) so I don't have to keep track of which end to put the rail on when boring my holes.

I'm thinking two stretchers per sysport to keep everything square and then attaching a 1/4" back. I've cut enough parts to make two sysports. My first design was one double wide sysport with a center divider. It was too fussy getting the center panel perfect and if you're off a mm it messes with the Sys-Az drawers.

I'm new to woodworking in general and am slowly wrapping my head around all of this 32mm stuff.

 

[Sparktrician]

Way to go, Matt!!!  [big grin]

 

[jimbo51]

I will post a picture of my completed Sysport soon I hope. It is about 6 ft long, 4 ft tall and 2 ft deep. It is designed to fit into a large steel shelving unit. The Systainers will sit sideways, 4 to a row and back to back using offset 14" drawer slides. When I recover from this adventure, I will make another one about 30 inches tall to go into the same steel shelving unit.

I do not mean to brag, but I am reasonably confident that I have made most of the possible mistakes one can make when using plywood and the LR 32 system; a whole column of misaligned holes, through holes not bored to full depth, blind holes bored through, some scars on a surface from a truly mindless mistake, solid wood trim getting chewed up from various causes, etc. I decided to just patch and continue rather than dumping any of the pieces and starting over. I have used a considerable amount of wood putty and spent a fair mount of time with the RO 90 doing repairs. In the end, it will be functional if not exactly aesthetically pleasing.

 

[DynaGlide]

Here's how I do a spot check that my parallel stops for the LR32 are even and touching before clamping down:

Panels are done, awaiting dominos:

Took a break to re-square my rail using a tip I picked up here:

 

[papester]

DynaGlide,

Would you happen to have the item numbers of the panels you bought from Lowes?

 

[TSO_Products]

[member=65062]DynaGlide[/member] -congratulations for jumping in with a picture story of your SYSPORT build and including your “lessons learned” for others to benefit from (i.e. the difficulties involved when trying to build multiple sections as one unit).

Your efforts and the interest of others over time convinced us to bring out fully engineered and tested SysPort plans and other designs in our new line of TSO Plans. As I write this,  the validation build based on our new Plans is in process. It will be used to develop instructions. The idea is to provide some very affordable but solid documentation a customer can duplicate or use as a starting point to modify to suit.

Look for more on this in a TSO INSIDER  by Labor Day.
Matt, meanwhile Keep on posting as you progress in that spiffy shop space of yours [smile]

Hans

 

[DynaGlide]

DynaGlide,

Would you happen to have the item numbers of the panels you bought from Lowes?

[member=63872]papester[/member] Here are the ones you want: https://www.lowes.com/pd/Thermally-Fused-Laminate-0-75-in-D-x-97-in-L-x-15-75-in-W-White-Shelf-Board/50386832 They're perfect width for this application. All you have to do is cross cut them square to desired length. One shelf will net you 2 sides, or 4 tops/bottoms, with the sides 1024mmx400mm and tops/bottoms 465mmx400mm.

[member=65062]DynaGlide[/member] -congratulations for jumping in with a picture story of your SYSPORT build and including your “lessons learned” for others to benefit from (i.e. the difficulties involved when trying to build multiple sections as one unit).

Your efforts and the interest of others over time convinced us to bring out fully engineered and tested SysPort plans and other designs in our new line of TSO Plans. As I write this,  the validation build based on our new Plans is in process. It will be used to develop instructions. The idea is to provide some very affordable but solid documentation a customer can duplicate or use as a starting point to modify to suit.

Look for more on this in a TSO INSIDER  by Labor Day.
Matt, meanwhile Keep on posting as you progress in that spiffy shop space of yours [smile]

Hans

[member=59331]TSO Products[/member] Hans, I may be in touch with you to send my guide rail square in for machining to attach to the hinge. I am thinking about picking up a third MFT to have as my "TSO rail" station. I look forward to your new products. .especially the Domino box jig you keep teasing.

 

[TSO_Products]

Off topic –
[member=59331]TSO Products[/member] Hans, I may be in touch with you to send my guide rail square in for machining to attach to the hinge. I am thinking about picking up a third MFT to have as my "TSO rail" station. I look forward to your new products. .especially the Domino box jig you keep teasing.
Matt

REPLY for All:
updating existing GRS-16 PE Guide Rail Squares to add (2) tapped holes for connecting to MFT/3 hinge bracket:
free download template and instructions for drilling and tapping.
https://tsoproducts.com/plans-drawings/grs-16-pe-template-for-adding-tapped-m6-holes/

Hans

 

[DynaGlide]

You know the darnedest things happen when you leave two MFT's together. . .

This one came with the MFT connectors and a spare fence securing clamp doohickey. I got this one and the Basic table on the left for a song. . combined they were less than a brand new MFT/3.

 

[Dick Mahany]

You know the darnedest things happen when you leave two MFT's together. . .

This one came with the MFT connectors and a spare fence securing clamp doohickey. I got this one and the Basic table on the left for a song. . combined they were less than a brand new MFT/3.

I don't even see a saw kerf on that one !

 

[DynaGlide]

Ahh that's better. I'm thinking using the second fence as off cut with tape applied a la Half-Inch Shy, and squeezing in the [member=59331]TSO Products[/member] guide rail square mounted to the MFT hinge on the right table for when I cut materials different heights.

[member=59951]Dick Mahany[/member] There isn't one  [wink]

 

[pettyconstruction]

Man I can’t seem to pull the trigger on one ,let alone 3.
Nice setup you have there.
Charlie

Sent from my iPad using Tapatalk Pro

 

[DynaGlide]

My inexperience with the Domino is showing through now.

I accidentally referenced off the wrong face on the left side panel top portion so went and re-did it on the proper face. .extra slop to those mortises. My little Sys-AZ spacers seem to fit pretty well, a bit snug in some spots but I think it'll do. I tried putting the whole Sys-AZ assembly in and it fits. Now the question is what to do to square everything up. I made some 19mm 100mm x 427mm stretchers out of off cuts of the melamine but they don't seem to fit too well. I'm questioning if I made them square enough. I suppose I could run a groove to drop in a 1/4" back panel on the top/bottom/sides and cut the panel with the TSO square to make sure it is dead on. I'm leaning that direction.

 

[Dick Mahany]

Now the question is what to do to square everything up. I made some 19mm 100mm x 427mm stretchers out of off cuts of the melamine but they don't seem to fit too well. I'm questioning if I made them square enough. I suppose I could run a groove to drop in a 1/4" back panel on the top/bottom/sides and cut the panel with the TSO square to make sure it is dead on. I'm leaning that direction.

A well fitting square panel will go a long way to square it up and add rigidity.  If you have enough room behind the rear of the panel you could use stretches or glue and pin a few small fastening blocks to anchor the rear of the panel to the sides.  Those methods have worked well for me. 

That project is turning out nice.

 

[DynaGlide]

How about this solution. .? I can drill in from the sides to secure with those Confirmat screws I've read about. I had picked up some wider pieces of Melamine with no plans for them when at the store and was able to get 1024 x 427 out of it using the [member=59331]TSO Products[/member] square.

I knew there was a reason I needed a 3rd MFT

Can I do the Confirmat route with a hand drill? Special bits required etc? Or just use Melamine glue and parallel clamps?

 

[TSO_Products]

Matt,
try the Confirmat drilling and  installation on some scrap melamine panels to learn what to look out for. More than just a couple of screws.
Hans

 

[Dick Mahany]

How about this solution. .? I can drill in from the sides to secure with those Confirmat screws I've read about.
Can I do the Confirmat route with a hand drill? Special bits required etc? Or just use Melamine glue and parallel clamps?

I think the confirmat screws would work fine.  There is a special combo drill bit and countersink (maybe Snappy?).  Mine is labelled 5x40 and has a brad point, but I think one could make do with other bits.  A hand drill would be okay IMHO as that's what I have done in the past.  No matter what method I use to square cabinet boxes up, there is just nothing like the simple cross checking across diagonals to be sure.

[attachimg=1]

 

[DynaGlide]

[member=59331]TSO Products[/member] [member=59951]Dick Mahany[/member] Got it. I'll get those and clamp it square before driving them in.

While this approach is working... What should I have done differently? I feel like this is the dumb method.