SYS-GRP FS Rail Guide & FAQ

At-a-glance

  • Works with: Festool FS profile rails and compatible extrusions (Festool, Makita, Milwaukee; Ridgid likely). Not compatible with Bosch/Mafell profiles.
  • Best results on: Smooth, sealed, rigid sheet goods; even spacing of pods along the rail.
  • Not recommended: Highly porous or textured surfaces without adjustment; vertical use without pre-op testing.
  • Key links: Vacuum sources • SYS-GRP Hub / valve kit • Warranty

1) Getting started

  • What it is (one sentence): Rail-mounted vacuum pods that secure your track saw rail to sheet goods quickly and repeatably without mechanical clamps.
  • Typical setup: 2–3 pods spaced evenly along the rail; add more for longer rails or vertical work.

2) Compatibility

  • Rails (confirmed): Festool FS, Makita, Milwaukee. Ridgid is profile-similar and expected to work.
  • Not compatible: Bosch, Mafell rails (different geometry).
  • Grabo use: Works with Grabo Pro-Lifter 20 and DeWalt Grabo via SYS-GRP Nexus Baseplate. Nexus distributes vacuum to connected pods. See SYS-GRP Nexus + Grabo Guide & FAQ.

3) Installation & setup

  1. Slide pods onto the rail from an end.
  2. Space pods evenly along the rail length.
  3. Connect vacuum tubing to each pod, then to your vacuum source (Nexus + Grabo or a dedicated pump).
  4. Lightly press to seat gaskets, then engage vacuum.
  5. Verify alignment and hold before cutting.

4) Performance & specs

  • Holding depends on vacuum level, surface, and contact. Suitable for rail positioning on sealed sheet goods and many textured materials with adjustments.
  • Materials guidance: Excellent (pre-finished ply, melamine, laminates, sealed MDF, tile/stone). Good (raw ply, sealed hardwood, painted/finished). Adequate with adjustments (raw MDF, unfinished softwood, textured).

5) Vacuum & power

6) Use cases & techniques

  • Horizontal cuts: 2 Maximus or 3 Hydraeus pods handle most cases; space evenly.
  • Long rails: Medium (1400–1700 mm) → 2 pods. Long (>1700 mm) → add one (Maximus 3 total, Hydraeus 4 total).
  • Vertical work: Always test on your surface; add pods on long rails; expect more variability.
  • Alignment tips: Seat lightly before vacuum; verify squareness; push-test before cutting.

7) Safety

  • Test holds before any cut, especially on vertical surfaces or porous materials.
  • Keep hands clear; confirm the rail cannot shift under expected tool loads.

8) Maintenance

  • Clean gaskets: Wipe with a damp cloth; avoid solvents/oils and soaking.
  • Replace gaskets: When hold degrades, deformation persists, or visible wear appears.

9) Troubleshooting

  • Pods not holding: Clean/seat gaskets, check vacuum, review material porosity, verify tubing, inspect gasket wear. Quick isolate test on melamine/pre-finished ply.
  • Vacuum runs continuously: Normal on porous materials; cycling depends on surface and joints.
  • Rail shifts: Add pods, space evenly, seat before vacuum, verify vacuum, push-test. Single-operator control: Accessory valve kit https://forg3d.store/products/sys-grp-fs-rail-accessory-valve-kit.

10) Ordering, warranty, and support

FAQ

FAQ — Quick answers

  • What rails are supported?
    Festool FS and compatible profiles (Festool/Makita/Milwaukee; Ridgid likely). Bosch/Mafell are not supported. See deep dive
  • How many pods do I need?
    Two for medium rails; add a third (Maximus) or fourth (Hydraeus) for long rails or challenging setups. See deep dive
  • Can I use it vertically?
    Yes. Test first. Add pods on long rails and account for material variability. See deep dive
  • Do I need to press down on the pods?
    A light seat helps the gaskets make full contact before engaging vacuum. See deep dive
  • How do I keep the rail from lifting or shifting?
    Space pods evenly, seat lightly, verify vacuum, and push-test before cutting. See deep dive
  • Why is my vacuum running continuously?
    On porous/textured materials, continuous running is expected as the system maintains pressure. See deep dive
  • What vacuum source should I choose?
    See recommended sources and fittings. Guidance
  • How do I keep performance consistent over time?
    Keep surfaces clean, seat before vacuum, use an inline filter, and replace gaskets when worn. See deep dive
  • Warranty?
    Covered by FORG3D’s standard warranty. Details

FAQ — Deep dives and field notes

How do I attach the FS Rail Vacuum Pods to my track saw rail?

The FS Rail Pods are designed to clip directly onto your Festool-compatible track saw rail.

Basic Installation:

  1. Slide the pod onto the rail extrusion from either end
  2. Position pods evenly along the length of your rail
  3. Connect vacuum tubing to each pod
  4. Connect tubing to your vacuum source (Nexus + Grabo or dedicated pump)

For detailed step-by-step installation with photos and video, see our full setup guide at forg3d.store/pages/fs-rail-setup.

First Time Setup Tip: Start with 2 pods evenly spaced. You can add more for longer rails or challenging materials.

What vacuum source do I need?

The FS Rail Pods require a vacuum source to generate holding force. You have several options depending on your setup.

Portable Options (via Nexus Baseplate):

  • Grabo Pro-Lifter 20 — Requires SYS-GRP Nexus Baseplate as interface
  • DeWalt Grabo — Requires SYS-GRP Nexus Baseplate as interface
  • Great for field work, mobile setups, and jobsite applications

Fixed Shop Options:

  • Dedicated vacuum pump — Provides stronger, quieter, more consistent vacuum
  • Best for bench-mounted or permanent installations

Recommendation: For occasional or mobile use, Grabo + Nexus is excellent. For daily shop use with larger panels or longer sessions, a dedicated vacuum pump will provide better performance and less noise.

See recommended sources and fittings here: https://forg3d.store/blogs/news/choosing-the-right-vacuum-source-for-sys-grp-workholding

How many pods do I need for typical cuts?

The number of pods depends on your rail length and application.

Standard Horizontal Cuts:

For most horizontal applications, 2 Maximus pods or 3 Hydraeus pods are sufficient to keep your track in place on most surfaces.

Longer Rails:

  • Medium rails (1400–1700 mm): 2 pods recommended
  • Long rails (>1700 mm): Add an extra pod
    • Maximus (310 mm footprint): 3 total pods
    • Hydraeus (90×90 mm footprint): 4 total pods

Vertical Applications:

  • Rails >1700 mm: Add extra pods beyond the standard recommendation
  • Pre-operation testing recommended due to wide material variances in vertical work

Single-Operator Tip: For long rails, consider our accessory valve kit so you can position and engage the rail from the center before engaging the outer pods.

Pod Models:

  • Maximus: 310 mm footprint — standard for most applications
  • Hydraeus: 90×90 mm footprint — developed for vertical siding where longer pods would cross joint lines; also useful where a compact footprint is advantageous

Which track saw systems work with the FS Rail Vacuum Pods?

The FS Rail Pods are designed to work with track saws that use the Festool FS rail profile or compatible extrusions.

Confirmed Compatible:

  • Festool FS Rails — Primary design target, fully tested
  • Makita Track Rails — Tested and confirmed, matches Festool profile exactly
  • Milwaukee Track Rails — Profile matches Festool/Makita; pods interchange without issue
  • Ridgid Track Saw — Not specifically tested, but uses similar extrusion to Makita/Milwaukee. Should work without issue based on profile match

Not Compatible:

  • Bosch Rails — Rail design is not compatible with our pod geometry at this time
  • Mafell Rails — Not compatible with current pod design

General Rule: If your track saw rail has a profile similar to Festool FS (which includes most major brands like Makita, Milwaukee, and Ridgid), the FS Rail Pods should work. Bosch and Mafell use different extrusion profiles and are not currently supported.

Can I use these with my Grabo?

Yes. The FS Rail Pods work with both the Grabo Pro-Lifter 20 and DeWalt Grabo when paired with the SYS-GRP Nexus Baseplate.

What you need:

  • FS Rail Vacuum Pods (typically 3-pod setup)
  • SYS-GRP Nexus Baseplate
  • Grabo Pro-Lifter 20 or DeWalt Grabo
  • Vacuum tubing (included with Nexus)

The Nexus acts as the interface between your Grabo and the FS Rail Pods, distributing vacuum across all connected pods.

Related: See SYS-GRP Nexus + Grabo Guide & FAQ for Nexus + Grabo setup and behavior.

What materials can I hold with the FS Rail system?

The FS Rail Pods can hold a wide range of sheet materials, with performance varying based on surface characteristics.

Excellent Hold:

  • Pre-finished plywood (sealed surfaces)
  • Melamine panels
  • Laminate countertops
  • Sealed MDF
  • Tile and stone

Good Hold:

  • Raw plywood
  • Sealed hardwood panels
  • Painted or finished surfaces

Adequate Hold (may require more vacuum pressure or additional pods):

  • Raw MDF (porous, may require continuous pump operation)
  • Unfinished softwood
  • Textured surfaces

General Rule: Smoother, sealed surfaces provide better vacuum retention. On porous materials like raw MDF, your vacuum source will cycle or run continuously to maintain pressure — this is expected behavior, not a defect.

Do I need to press down on the pods to get them to seal?

A light downward press on each pod helps seat the gaskets and ensure full contact — especially on textured or uneven materials. This step also keeps the pods from lifting the rail slightly, which could throw off squareness along a cut. A gentle push ensures full engagement without affecting alignment.

Tip: Think of it as "setting" the pods, not forcing them down. Once vacuum is applied, the seal does the work.

How do I ensure my rail stays straight and doesn't lift?

To maintain rail alignment during your cut:

  1. Position pods evenly along the length of the rail — avoid clustering them all at one end
  2. Seat each pod with light pressure before activating vacuum to prevent the rail from lifting
  3. Check rail alignment after vacuum is engaged and before starting your cut
  4. Ensure adequate vacuum pressure — insufficient vacuum can allow the rail to shift

Pro Tip: On longer cuts (2700 mm+), using 3 pods evenly spaced provides better stability than 2 pods at the ends.

Why does my vacuum source keep running continuously?

This is completely normal and usually tied to the surface material, not the FS Rail Pod system.

Expected Behavior:

  • On sealed surfaces (melamine, pre-finished plywood), your vacuum source may cycle on and off as it maintains pressure
  • On porous materials (raw MDF, unfinished wood), the vacuum source will typically run continuously to compensate for small air leaks through the material
  • Even on non-porous materials, small imperfections or surface variations can prevent auto-shutoff

This is not a defect. The FS Rail Pods create multiple sealing points, and slight vacuum loss is expected. Perfect sealing at every junction would require costly, high-tolerance machining — which goes against SYS-GRP’s design principle of accessible, real-world vacuum workholding at a practical price point.

The rail shifts during my cut — how do I prevent this?

Rail shifting is usually caused by insufficient clamping force or uneven pod placement.

Prevention Steps:

  1. Add more pods — For rails over 1700 mm, add an extra pod (3 for Maximus, 4 for Hydraeus)
  2. Space pods evenly — Avoid clustering pods at one end; distribute them along the rail length
  3. Seat pods properly — Press down lightly on each pod before engaging vacuum to ensure full gasket contact
  4. Check vacuum pressure — Weak vacuum means weak hold; verify your source is providing adequate pressure
  5. Test before cutting — Apply vacuum and give the rail a firm push to confirm it's secure

For Long Rails (Single Operator): Consider using our accessory valve kit to position and engage the center of the rail first, then engage the outer pods. This prevents the rail from shifting while you're setting up.

Vertical Applications: Always perform pre-operation testing when using pods on vertical surfaces due to material variances and gravity working against the hold.

How do I clean and maintain the gaskets?

A light wipe-down with a damp cloth is all you need to clean the gaskets and keep them sealing properly.

Important:

  • Do not expose gaskets to chemicals — solvents, cleaners, or oils can degrade the gasket material
  • Avoid large quantities of water — gaskets should be wiped, not soaked

Quick Tip: Clean gaskets before each use if you’ve been working in dusty or debris-heavy environments.

When should I replace the gaskets?

  • Reduced hold strength or inconsistent seal
  • Permanent deformation that doesn’t recover
  • Visible wear: cracks, tears, compression marks, or surface damage

Replacement parts?
Yes. Contact us for replacement gasket material and hardware: https://forg3d.store/pages/contact