Fooled you.
I've been kicking around the idea of using aluminum extrusion for SysPorts and finally found a (relatively) affordable vendor: Misumi. This design uses their 30x30mm extrusions, which are significantly more affordable than the next size up (40x40) yet plenty strong for this application. I'm expecting the extrusions to cost in the ballpark of $500 for this project, which really isn't bad and significantly less expensive than 80/20 Inc. Of course, it's the fittings that kill you, but I'm using either the most affordable brackets Misumi offers or re-using some existing hardware (t-nuts, screws, etc) to try to keep the costs down.
I've sized this to perfectly house the Kapex in the middle, with the plywood overhang mating right up against the edges of the Kapex work surface. Height of the miter saw mount can be adjusted easily, and also replaced in the future for a different saw. I toyed with some dust collection shrouds or a downdraft table, which I can always add later, but decided to keep it simple
![[eek]](https://www.festoolownersgroup.com/Smileys/default/eek.gif "Eek!")
for now.
This is a really long assembly (almost 15 feet long), designed to take up my entire back wall of the shop. Yet I still wanted occasional mobility, so I added some ball transfer switches (which I just recently discovered, super cool as they are extremely low profile but many are able to take a lot of weight) and leveling pads that screw into the bottom of each extrusion.
Of course, the appeal of aluminum extrusions is total flexibility in mounting the 31x SYS-AZ drawers. I'm planning on mounting the bottom drawers first, then using a plywood sheet as a spacer to ensure a consistent gap between each cabinet. Spacing at the top will be variable, which is fine as I'll need to provide some space underneath the perforated top for clamps to pass through without interfering with the systainers. The spacing between each extrusion will be a perfect 427mm, driven by the CNC holes on the top and bottom plywood panels.
One problem I've always had with my homemade SysPorts is balance. My first SysPort is always threatening to tip forward if I just look at it wrong. A follow-up design I made had some hidden storage shelves on the back, just to counterbalance it. In this case, I also ended up with substantial space behind the drawers due to the overall depth of the work surface. I wanted a 22" deep countertop to allow for storage of, sadly, additional systainers along the back if necessary. I've tried to put that back space to use with some rail storage and shelves for longer items like straight edges.
I'm aiming to cut the plywood and acrylic for the flag stop with a Shaper Origin.
I'm not going to tackle this project for another month or so, but interested in getting any input or design improvements now. Happy to share the 3D or DXFs files and material list if there is interest.
