Dewalt Tough System Van racking

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Dewalt Tough System Van racking

Postby Rossi7x » Sun Aug 30, 2015 10:19 pm

Right Guys....

Due to ever increasing interest in this idea, I though we'd start a dedicated thread to How to Build one, and all the Variants that currently, and increasingly exist..

Would like to keep this on track as an informative 'How to Guide' with Q's and A's, rather than who loves it or loathes it, as there are other general Van racking threads on here for that..

Who knows.. If it gets enough 'Thumbs Up' it might even become a 'Sticky'...

So for those interested to see how simple this is to build, here we go..

The Metal tubing os 25mm Box section with 2mm walling, and it came as a total cost of £68 to do this..

Here's how the basic Sketches (and sizes) started...

This rack is for 3 rows, of 4 boxes high (DS400 on the floor, 1 x DS300 above and 2 x DS150's above that)

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Last edited by Rossi7x on Sun Aug 30, 2015 11:25 pm, edited 1 time in total.
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Re: Dewalt Tough System Van racking

Postby Rossi7x » Sun Aug 30, 2015 10:26 pm

All 'Tube laid out ready for Tack welding..

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You will notice that there is a 'Double vertical ' Tube on the ends of the racks and also vertically at intervals as per the original sketch.. The one's in the centres are to create the 'Minimal' gap required to keep the boxes close enough together so as not to waste space, but far enough apart to give the minimal space required to lift the locking handle on the boxes..

The 2 pairs of vertical bars on the racking extremities are purely for the Dewalt folding arms (inner bar), and to 'dress' some ply on to hang the Dewalt trestles (all will become apparent as the build goes on) on the outer bar.

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Once tacked and Squared, all welds are finalised and smoothed for powder coat..

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Last edited by Rossi7x on Sun Aug 30, 2015 11:28 pm, edited 1 time in total.
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Rossi7x
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Re: Dewalt Tough System Van racking

Postby Rossi7x » Sun Aug 30, 2015 10:33 pm

A top rail was welded and fitted according to whatever Angle is required for your own particular Van, with M12 holes drilled to suit...

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Bolt Holes drilled..

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Rear of it is shaped to take the 'slope at the Back and of a T5...

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Foot plates are welded to the 2 outer 'Long' legs of the rack

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Time spent smoothing and linishing welds makes for a better Powder Finish...

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Re: Dewalt Tough System Van racking

Postby Rossi7x » Sun Aug 30, 2015 10:44 pm

Back of a T5 before any racking was fitted... Pretty much an empty space where you'd only general use the floor-space...

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Before test fitting, back of Rack was drilled with numerous holes (at Inch Centres) to suit varying box heights. Multi drilling at this stage is a pain, but future proofs the racking for every eventuality...

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Even on the Centre tube, the same drilling was done..

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You might notice that on a couple of the down tubes, they are slightly shorter than others.. This is to accommodate the wheel arch, and to enable the rack to move as close to the side of the Van as possible..

When 'Test fitting the Racking frame, holes were marked in the 'Structural' top rail of the Van, a 14mm Hole drilled to suit, and then a 'T' nut welded in to give a threaded bolt hole to enable the racking frame to be removable if necessary..

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For those that have seen the Van on the Net or in person, you will know that there is a set of Wooden Shelves. These are also constructed around a metal frame work that bolts in and out to suit...

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Re: Dewalt Tough System Van racking

Postby Locksmithmatt » Sun Aug 30, 2015 10:53 pm

I done the same with the uprights , putting all the holes in is time consuming but that is the beauty of the racking , it can be adjusted in the future if needs be to adapt to other box sizes


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Rossi7x
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Re: Dewalt Tough System Van racking

Postby Rossi7x » Sun Aug 30, 2015 10:56 pm

As you can see, bolting the rack in takes a bit of effort with welding the 'T-Nut' in pace, but for re-sale of the Van you could 'Plastic cap' them to hide, and in the event of the Van being sold or involved in an Accident, it can be removed very easily..

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As you can see, it's a very simple frame-work to construct.. If you can't weld, then you could 'Captive Nut' and bolt, or just plain 'Nut and Bolt it together..

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With all the holes drilled in the rear, it's easy to pick and choose where you want to fit what boxes..

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Folding arms.. Genius Idea from Dewalt.. Full width of Van back in seconds making this kind of Racking truly unique and versatile over others..

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Last edited by Rossi7x on Sun Aug 30, 2015 11:31 pm, edited 2 times in total.
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Re: Dewalt Tough System Van racking

Postby Rossi7x » Sun Aug 30, 2015 10:59 pm

Its amazing that with a little bit of Yellow flooring (wonder why it was that colour lol) a Bit of Creative Ply work and some carpeting, the build takes on a whole different level...

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And remember that small spindly rack on the opposite side.. Here it is 'Clad' in Ply, complete with Dovetail to keep even the most critical woodworkers smiling...

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Re: Dewalt Tough System Van racking

Postby DAZ40 » Mon Aug 31, 2015 8:26 am

That's a work of art my van never look that tidy
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Rossi7x
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Re: Dewalt Tough System Van racking

Postby Rossi7x » Mon Aug 31, 2015 11:18 am

As well as the main parts of the rack on each of the side walls, I also have a removable 'side door rack' which really adds to the storage capabilities of the Van..

Here it is in Situ on the initial Dry test..

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And in relation to the rest of the racks..

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It was initially decided to go more maximum 'Tough Box' storage, allowing for 9 DS300's to be fitted behind the bulk-head.. It wasn't long before it turned out to be as much of a negative as a positive, so the rack was swiftly modified to half the size. In fact, making it more versatile to use..

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This Side rack currently being re-worked 'again' to allow for a pair of Drawer runners to Double extend to 2100mm long, so that the 350KG weight loaded runners can allow me to place a DW745 table saw on them, with a fully loaded DS400 behind, and slide them completely into the Van and lock in position, and when needed, fully extend to well outside the Perimeter of the Van itself...
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Rossi7x
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Re: Dewalt Tough System Van racking

Postby Rossi7x » Mon Aug 31, 2015 11:23 am

Quick shot of the Ply Work at the rear of the Van.. Plunge saw rails are really important to my daily work life, that they featured pretty high up in my 'Racking Requirements'.. This was my solution.. A bespoke 'Pocket' to stop them coming into contact with anything else...

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And for those that have thought I've missed a trick, yes there are 'access' holes router to the underside of the pocket to a) reduce weight, and b) to allow you to remove any of the shorter rails the 'Apprentice' slides down the pocket in their stupidity...

You'll even notice there is a groove 'top' and 'bottom' of the Pocket.. This is a) to reduce the height requirements of storing 2 rails back to back, and also to stop them sliding left to right and potentially damaging the splinter guard...

Now, If I was really clever at the time, I would have also routed a sot in for my Festool rails too... Hey ho..!!
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