Frank,
Great job on those replacement inserts. I was hoping you could answer a few questions on their construction:
Did you just glue and nail the boxes together?
Are the bottoms butted to the sides or in a dado?
How heavy would a loaded sys 4 be? I'm thinking of doing this but as a general contractor, I carry quite a few tools with me, so I thought I would be better off with a sys 5 do you think the extra size would make it too awkward? Currently my hand tools are stored in a large shipping container with custmized inserts. I'm hoping I can pair down some of the tools and squeeze the remaining into a sys 5... I don't know though, there's a lot of stuff in there.
Thanks,
Michael