One of our favorite types of projects in the shop is, well, a shop project. Recently, we added a Festool CSC SYS 50 to our arsenal for a number of upcoming 'out-of-the-shop' needs, but also to help streamline various in-shop operations. For these in-shop needs, a new shop cart was necessary.
For the cart, we had a few critical requirements:
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Small footprint – Shop space is always at a premium, and a new tool and cart can quickly become an encumbrance if they don't fit into the space and workflow.
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Self-contained – To optimize our workflow and the needs that the CSC SYS 50 addresses in the shop, all accessories, dust extraction, and the tool itself needed to be integrated into the cart to remove as much friction as possible.
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Height – The height was critical to ensure the cart was self-contained and allowed us to use it in conjunction with our primary workbench as an outfeed in the event that larger ripping operations needed additional support.
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Practice – How is practice a requirement? In addition to the CSC SYS 50 arriving in the shop, a new Lamello Zeta P2 also landed to be used on some of the same upcoming projects. So, integrating the Lamello into the build workflow was essential for us to prepare for its use on other projects we have in the pipeline.
Now, let’s get into the design and build.
The design was dictated by the criteria laid out above. We needed a small but stable footprint that held the saw, the accessories, and a CT MIDI dust extractor (or CTC MIDI as a possible future option). We also wanted to incorporate the Benchdogs UK CSC SYS 50 Accessory Systainer into the cart to keep everything we might need with the saw together. Adding all of that up, along with meeting the prescribed height of our workbench for outfeed, meant we had to audition a couple of different caster options to arrive at the final solution.
As with any project that involves plywood, the first step was to break down our sheet goods. Our Festool TSC 55 and TSO parallel guides made quick work of breaking down a sheet of leftover plywood from a previous project. We also got to use the CSC SYS 50 to rip a few leftover strips of plywood to 100mm for the upper stringers. So, a little tool and project inception occurred—using the tool we were building a cart for without the cart itself, to create the cart needed for the tool.
After getting our sheet goods to width, we headed to the workbench to crosscut the material. Again, our TSC 55, along with our Benchdogs UK Fence and Dashboard PWS Guide Rail bracket, made it easy—and, most importantly, repeatable—to get everything to its final length. We can't say enough good things about both of these systems and companies; both are small businesses that produce amazing products solving real problems in the shop.
With all of our parts cut to their final dimensions, it was time to tackle the joinery. For most shop projects, simply screwing the parts together is often more than adequate. However, one of our requirements for this project—and for many shop projects we tackle—is to use new techniques or tools to practice for real production pieces or commissions that may lie ahead. This time, it meant trying out the Lamello Zeta P2 and its P-system connectors for the first time. Now, we fully admit that using Tenso connectors and Dominos on a shop project might seem like overkill, but we wanted to practice, so it was time to layout for the joinery.
Having used Dominos for years and knowing how critical it is to keep reference faces straight, the process was a bit easier. However, blending two different joinery systems meant that layout and marking were a bit more involved than when using just one. Our plan was to use Dominos along the bottom panel of the cart to improve sheet strength and utilize the Tenso connectors and glue along all other joining surfaces for a strong, clamp-free, and visible fastener-free connection.
Our first attempt at mixing joinery methods didn't go off without a hitch, as you can see in the picture. During our dry fit, we found that we had gotten a bit ahead of ourselves and plunged a Domino mortise in a location that was intended for a Tenso slot. But that's why you practice on shop furniture. As for other mistakes made, you might ask, 'Why didn't you rip a clean edge on the plywood?' After seeing the factory marks for the Garnica ply in the photo, we hoped to save material since we were very close to not having the width needed. Therefore, we left the factory edge and ensured those marks were placed on the back of the cart.
After cutting all the required mortises and slots for our Dominos and Tenso connectors and doing a dry fit, we gave the panels a quick once-over with our Festool ETSC 150 and 180-grit sandpaper to remove all layout marks and achieve a nice smooth finish on all panels.
With all the panels sanded along the face and edges, it was time to bring everything together. We carefully laid out all our pieces, installed all our Tenso connectors in the correct slots before beginning to apply glue to the required surfaces. If you've used Tenso connectors, you know that positioning them can be a challenge. However, our buddy Keith Johnson has an amazing product in his shop that addresses this, so make sure to check it out.
We wanted the majority of the glue-up to proceed without needing clamps or screws. However, with the front stringer, we only used Dominos, so one clamp and a pair of squares were necessary to bring everything together. For all other surfaces, we relied on the 30 lb clamping pressure of the Tenso connectors to clamp the joints tight. This significantly reduced the stress of the glue-up: apply glue, insert the Dominos, and then enjoy the very satisfying snap of the Tensos, eliminating the need to wrestle with four or five different clamps.
While we waited for the Tensos to do their job and the glue to set up, we decided to practice with another one of our favorite tools in the shop, our Shaper Origin. One element that Festool built into their CSC SYS 50 UG stand was recesses to hook the CSC SYS 50 feet into the stand, ensuring a solid connection and eliminating the possibility of the tool shifting during operations. We wanted to replicate this feature in our cart, so we removed the rubber feet from the bottom of the CSC SYS 50 and used our Shaper Trace to quickly digitize the shape for use on our Shaper Origin.
Next, we headed to Shaper Studio for a quick cleanup of the trace, then back out to the Shaper Origin to start creating the pockets. With the shape ready on the machine, we could use the Shaper Plate to quickly register the shape with the appropriate alignment and offsets onto our Valcromat cart top. We are always blown away by the accuracy of the Shaper and the amazing fitment you can achieve as you sneak up on the perfect fit with interlocking parts.
With the carcass glued up, the flourishes of the recessed feet, and the majority of the build in the rearview mirror, it was time to tackle the last few items of this project: casters and accessories. There was nothing too exciting with the casters—just quick pilot holes and some cabinet screws to secure them in the correct place.
We also wanted to include one of our own accessories in the build—our SYS-RLZ Systainer3 Pro Rail Slides to house our Benchdogs UK Fence Systainer. Our SYS-RLZ allows a narrow mounting envelope, the same as standard Systainer3 rails, while enabling you to slide the Systainer3 out to access its contents without removing it from the rails. In the photos, you can see our SYS-RLZ mounting template in use to place the euro screw holes at the appropriate setback and spacing for easy installation.
The final results? Well, not exactly final, as we still have a few accessories to add to the cart. In reality, these products are in development and intended for the CSC SYS 50. Until those are ready for introduction, we are quite happy with the cart. It has a small footprint, is self-contained, meets the required height to leverage our workbench as outfeed, and allowed us to practice (and make mistakes) with new tools, checking all the boxes on the requirements we set out before we began. Overall, there aren't many things we would change.
If we were to change anything, better casters would be at the top of the list. However, for the height requirements, we were limited in selection, so we need to continue looking around for better options. The second issue is the best option for the dust extractor. Currently, we are using a CT MIDI we had in the shop, but would a CTC MIDI be a better option? We appreciate that the CT MIDI is always on and ready, but if we have to move the cart, worrying about the cord could become an annoyance. Only time will tell.
Last thoughts...
This was a fun project that allowed us to experiment with new tools in preparation for future commissioned projects. Regarding our insights on the new tools, the CSC SYS 50 is an amazing little saw—quick, accurate, quiet, and everything you'd expect from a Festool. We still have to put it through its paces to truly ascertain where it fits into our workflow, but for the first few weeks of having it in the shop, we are really enjoying it. The Lamello is equally an amazing tool and system. We added it to the shop for very specific use cases and are eager to see how else it can fit into our workflows and projects.
Not related to the tools, we encountered a couple of pain points during the build that sparked ideas for new products. Some simple solutions are already in preparation for testing, and there are even more interesting possibilities on the drawing board and in prototype. So definitely check back to see what mad science might be afoot!
Let us know if you'd like us to put together a set of plans for our little CSC SYS 50 cart so you can add it to your shop, or if you have any questions about any of the products we used on the project, be it our products or others!
All of the photos containing Forged 3D products contain links to their respective product pages.