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Track Saw Rail Organization

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Project by mtalley posted 07-09-2019 10:47 PM 476 views 4 times favorited 10 comments Add to Favorites Watch

I tipped over my 55” Festool track saw rail and bent it along the spine. There was no fixing it. I said DIRTY words. It has almost happened 20 times and I kept “meaning to do something about it…” That painful monetary loss was the final push I needed to get the track off the floor and out from leaning on the walls of my shop. My wife left me unsupervised for the weekend and I spent like 22 hours in the shop over a two-day period designing, prototyping, making, and installing a track saw rail organization system. That amount of solid non-wife time would have been bad juju if she were at home.

I do not have any easily accessed extra wall space, so I looked around, saw that both of my garage doors were empty and said, “Hmmm…” I decided to build a rack that would mount on the door, allow it to move without any removal of the rails, and keep the rails secure during the entire transit up and down. I ended up with a tiered slot design and because I have 5 different sized tracks, I made two sets of holders.

It took some figuring and I tacked together 2 mock-ups, before I got it right. Each hanger (8 total) is made from 3 sections of ¾” ply and 6 sections 3/16” ply, all laminated together with Titebond II glue and layers secured together with two secondary opposing wood screws. Each bracket is fastened to the door with three #10-1” Sheet Metal screws and are all within 1/32” level across the entire 9’ door. The door moves up and down freely and the track rails don’t budge during the entire transit.

Really proud of how these worked out and believed I was the smartest wood-sorcerer that hath ever cast man-glitter right up until I went on the Festool Forum to post/brag about my giant bucket of smarts and saw 4 VERY similar designs that were years old…

The video of the build is here:
https://youtu.be/6mgKI_rzHh4

I also put together a quick scale drawing of the brackets here:
http://mattofmanytrades.com/wp-content/uploads/2019/07/Track-Saw-Bracket_Matt-Talley_2019.pdf





10 comments so far

View lanwater's profile

lanwater

3113 posts in 3352 days


#1 posted 07-10-2019 02:58 AM

Excellent Idea!

I have a space problem too…

-- Abbas, Castro Valley, CA

View edapp's profile

edapp

283 posts in 1848 days


#2 posted 07-10-2019 12:18 PM

Fantastic Idea… I will likely copy this!

View rbrjr1's profile

rbrjr1

208 posts in 624 days


#3 posted 07-10-2019 03:22 PM

those look great..
love the final contouring with the drum sander..

-- only an idiot dismisses an intelligent statement because they dont know anything about the person delivering it.

View dustyal's profile

dustyal

1310 posts in 3893 days


#4 posted 07-10-2019 04:57 PM

Excellent idea. As with many of us, we are short accessible wall space. And I have been staring at the backside of my garage doors trying to figure out how to use that space. I’ll have to check clearances as my ceiling is exceptionally low but I think it is doable. Thanks for the idea.

-- Al H. - small shop, small projects...

View rbrjr1's profile

rbrjr1

208 posts in 624 days


#5 posted 07-10-2019 05:52 PM


Excellent idea. As with many of us, we are short accessible wall space. And I have been staring at the backside of my garage doors trying to figure out how to use that space. I ll have to check clearances as my ceiling is exceptionally low but I think it is doable. Thanks for the idea.
- dustyal

An idea that I was contemplating at one point was to install a pivoting lumber rack that would utilize the space against the door when it was down and would move out of the way when it was opened (even pivot outside if the door was going to stay open for a while)..

-- only an idiot dismisses an intelligent statement because they dont know anything about the person delivering it.

View mtalley's profile

mtalley

111 posts in 1894 days


#6 posted 07-10-2019 08:27 PM



Excellent idea. As with many of us, we are short accessible wall space. And I have been staring at the backside of my garage doors trying to figure out how to use that space. I ll have to check clearances as my ceiling is exceptionally low but I think it is doable. Thanks for the idea.

- dustyal

Thank you. I don’t have the ceiling issue, but I used to in my old shop, so I understand. I hop it works out for you.

View mtalley's profile

mtalley

111 posts in 1894 days


#7 posted 07-10-2019 08:30 PM



those look great..
love the final contouring with the drum sander..

- rbrjr1

Thank you. I like the way it looks and I added the contoured transition so that one of the lower rails would not get caught on the one above when I was taking them out. I am working on a YouTube video of the build and installation and go over that feature. Video should go live tonight. Will add a link in the comments when it does.

Matt

View mtalley's profile

mtalley

111 posts in 1894 days


#8 posted 07-10-2019 08:33 PM



Fantastic Idea… I will likely copy this!

- edapp

Thank you! I didn’t know folks would like these so much. I will post a drawing of the bracket tonight.

View mtalley's profile

mtalley

111 posts in 1894 days


#9 posted 07-11-2019 08:49 AM

The video of the build is here:
https://youtu.be/6mgKI_rzHh4

I also put together a quick scale drawing of the brackets here:
http://mattofmanytrades.com/wp-content/uploads/2019/07/Track-Saw-Bracket_Matt-Talley_2019.pdf

View rbrjr1's profile

rbrjr1

208 posts in 624 days


#10 posted 07-12-2019 12:55 PM

looks great..

I didn’t realized that you installed them ON THE DOOR PANELS…

If you’re looking for an extra layer of security for the guides, you can always get some bungee cord and add some “keepers” that run from a small screw in eyelet at the top of the lowest bracket and secure over a small screw in hook at the top of each hanger.

I use something similar to keep a 4’ ladder mounted on the back of my shop door.

ounce of prevention, pound of cure, ya’ know…?

-- only an idiot dismisses an intelligent statement because they dont know anything about the person delivering it.

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