Author Topic: Economy double sysport concept made of AL extrusions  (Read 1629 times)

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Offline ryanjg117

  • Posts: 200
Economy double sysport concept made of AL extrusions
« on: June 30, 2019, 11:37 PM »
Some of you know I've been kicking around various ideas for sysports with AL extrusion for some time, including a bit of an over-the-top miter saw station with systainer storage beneath:

A cool concept, but after tallying up the costs of the extrusion, connectors and hardware, it would have been well over $1,000. Maybe closer to $2,000 USD. I'm at the point now where I need to get moving on building some additional systainer storage, so I went about trying to design a double sysport as economically as possible. A few of my design requirements:

  • Capability to be bolted together
  • Casters for mobility but adjustable mounting feet for stability (these will seldom be moved)
  • Related to previous, but the ability to level it, especially important as I'm going to be connecting these together and they will form the platform for my miter saw station

Here's my current result:

Still using extrusions for the uprights and an open design. After pricing out 80/20 Inc. and comparable suppliers, Misumi (at least here in the states) appears to be far and away the cheapest supplier. This design uses their Series 6 Base 30 extrusion (30x30 mm profile), and each upright is 976mm long. I found this height to be about the maximum for me (I'm 5'10" tall) while still having a tabletop working surface. This particular extrusion is unique in that it is relatively small, but still has a full 10mm channel, which means the Festool clamps will slide right in without a problem. The best part - each upright costs only $9.76 USD.

Right now, with the extrusions, spring nuts, socket cap screws, leveling feet and casters, I'm at about $119. This assumes four SYS-AZ drawers per stack, and the mounting hardware to secure them. This price doesn't including the top and the bottom (figure on 3/4" or thicker material for the top, and 5/8" material on the bottom). Also doesn't include shipping costs from Misumi, McMaster and Amazon. Still, under $150 for a double sysport made of extrusions isn't all that bad, especially when compared to Festool's 491922 steel single sysport at $725!

I'm going to build a few of these and report back on how they work. I'm also going to develop a couple of additional top designs, one with the 20x96mm hole pattern and other with slots for t-tracks, coming soon. Let me know if you'd like the DXF or Fusion 360 files.

Offline Jiggy Joiner

  • Posts: 887
Re: Economy double sysport concept made of AL extrusions
« Reply #1 on: July 01, 2019, 02:42 AM »
I really like your concept saw station, it looks very minimal but, very functional with great storage, shame about the expense.

Maybe don’t be too hasty just yet, as there are new Systainers coming that are different heights to the current version  ;)

Offline nvalinski

  • Posts: 105
Re: Economy double sysport concept made of AL extrusions
« Reply #2 on: July 01, 2019, 08:29 AM »
It looks super slick, but I have two thoughts on this. First, I have a feeling this will get wobbly quick, since there isn't much diagonal/lateral bracing like a skirt. Maybe having the drawer slides installed helps this, but I'm not sure. I also wouldn't want to rely on just 3/4" MDF to not sag and hold the top, so maybe a skirt would be beneficial.

Second thought, why bother with aluminum extrusion at all if there is no means to use it for clamps? I'd bring the extrusions flush with the front to be able to use it as a vertical clamping surface at least, otherwise maybe just solid plywood sides.

I do love the track storage in your first rendering.

Offline Mike Goetzke

  • Posts: 464
Re: Economy double sysport concept made of AL extrusions
« Reply #3 on: July 01, 2019, 08:45 AM »
Very nice and clean looking!

To cut cost further, is there a way to build your own pull-out trays to hold the systainers?


Offline Trevin

  • Posts: 99
Re: Economy double sysport concept made of AL extrusions
« Reply #4 on: July 01, 2019, 12:33 PM »
I did something similar to this in my shop.  I was fortunate to get all the 80/20 for free from an old employer who was clearing out one of their labs.  I love this system as it is very solid with no movement.
The only problem with 80/20 is I WANT MORE!
Festool: MFT3 (x2), OF1010, OF1400, LR32, Domino DF500, Domino XL DF700, Kapex KS120, TS-75, Carvex 420, CXS, C-18, Vecturo OS 400, DTS 400, Pro 5, Rotex 125, VAC-PMP, VAC-SYS-1, VAC-SYS-2, CT-26 (x2), CT-SYS, SYS Light DUO, SYS-ROCK
Other: Minmax FS41, Sawstop PCS (3HP, 52"), Laguna BX14, Jet 17" Drill Press, Rikon 70-220VSR Lathe, Incra LS Router Station, Laguna P/Flux 3 Dust Collector

Offline rst

  • Posts: 2288
Re: Economy double sysport concept made of AL extrusions
« Reply #5 on: July 01, 2019, 05:50 PM »
Have a metal fabbing shop make U pans and buy over travel slides.  I had mine made, with the slides for -$15.00 per drawer.  I cut the holes in the pans with a die grinder so that the rear holes capture the rear legs and the front legs drop into the holes.  Bought the over travel slides on Ebay for about $10.00 @.
« Last Edit: July 01, 2019, 05:56 PM by rst »