Modular Stackable Circular Saw Blade Storage Case (5.5"=7.25" inch blade, 5/8" Arbor)

Based on community feedback and requests, here is the latest addition to my blade storage system.

Instead of making a three different sized trays for 5.5", 6.5" and 7.25" blades, I have one tray that will fit all three. 

I also had feedback that went both ways on the size of the tray. There were some who wanted a tray that would be compatible with the 10" trays. Other people wanted a smaller package. I kind of did both.

It's a smaller, space saving, 195mm square. but if you want to stack these with your 10 inch blades, I included an "adapter lid" for the 10" version, in both the one piece and small plate versions. You can print this adapter and use it as the lid of your 10" and it has the studs to start stacking your circular saw blades on top of the table saw blades.

The standard guidance:

I recommend printing with 3-4 walls, 1 mm top and bottom layers (makes important parts solid), and 10%-20% of your infill of choice (I used gyroid).  I recommend not using PLA for the sake of the push button compliant mechanism in the middle and instead using PETG, ABS, or ASA.

For the small build plate version of the adapter lid:

Only print with a well tuned printer. Please realize that the fit of these pieces have to be very precise and if you have too much elephant's foot or skew or over extrusions or pretty much anything that messes with your dimensional tolerances, you're going to have a hard time getting these parts to fit cleanly for glue up.

While you could theoretically print this with a 0.2mm layer height, I printed my test pieces with 0.1mm layers to give the cleanest 45 degree slopes and overhangs in the scarfed section of the hidden dovetails. If you print with anything thicker, at least consider using "precise z" in your slicer so that the heights of the dovetails all end up right. I'd also be cautious with thick outer bridges. I left clearance, but YMMV. These sections are very thin and I needed to squeeze as much quality as possible out of these rather fine features

The small build plate adapter version requires 4x of the model. To assemble these, start by gluing together two sets of two. From there, place the middles together and twist them until the dovetails align and then use light pressure to squeeze them together. Try a dry fit before doing you gluing as you may need to use a knife or deburring tool to clean up any elephant's foot or over extrusion on the bottom/top surface to get a clean fit.

Still on the to-do list:

A dado set... Still making some design decisions on that one.

A 12" version for miter saw blades.