Milwaukee PACKOUT Rail Cup

Introduction

Hello, and thanks for looking at my model!

I live own a three decker which means that even though I own my own home I also live in an apartment. This creates problems for hobbies like model making, scratch building and miniature painting for wargaming due to space constraints. It's fine to spread out when working on a hobby but that stuff needs to be packed away as small as possible when not in use. Milwaukee PACKOUT was the perfect answer to this - mostly. I have changed the stack once as two new pieces came out but it still needed some adjustment to make it perfect for my needs.

One of the ways I've recently modified the stack to better serve is to add rails to hang bits on to let me store stuff that is a little harder to store in the drawers or cabinets without it taking up a pot of room, falling all over itself and being hard to find the thing I want. This cup is meant to slide over a piece 1/8" x 2" aluminum or steel flat bar stock. You can find the appropriate flat bar stock at your local home center. You can also find it online but unless you do not have a home center where you live or it doesn't carry metal stock this you can find it online from places like Amazon and OnlineMetals.com. The price might be a tad cheaper online but the shipping will eat past those savings so only use an online option if an in-person option is not available to you. You can also google your local area for metal suppliers or welding suppliers. Most areas have them but unless you've needed metal stock or welding you've probably never noticed them.

The design for this rail mounted cup was to hold the styrene and brass rods and strips I use in modeling and scratch building. They tend to just pile up in a drawer both taking up too much space and being hard to search through. In the PACKOUT cabinets they just fall all over the place and usually out onto the floor when the cabinet door is opened. This cup combined with my Upper Hoop model give me a nice close to hand place to keep these organized, ready to hand and easily searchable when I need something.

These currently just allow the rail to pass through them. I will come out with a version that can be fastened over the top of the rail in the near future. That will avoid having to take one or more extrusions out in order to install these. I made these to use in conjunction with my own rail adapters and with two on one side there's very little free space, only about 1/16" for them to slide around so you can probably skip the heat press inserts and set screws if using two on one side like I did. If only using one though you might wat to fix it in place on the rail.

There are holes on the back side big enough to allow a heat press inset press pass through without contacting the plastic. Pressing the inserts in from the back side allows me to take advantage of the stresses that will be involved when using a set screw to fix the adapter in place on the rail. There is a very slight lip on the front side of the hole for the heat press insert to serve as a stop when pressing from the back. When adding the set screw from the front then tension from the set screw pressing against the rail will act to try and press the heat insert through the entirety of the plastic at the front instead of acting to push the heat press insert out of the plastic like it can if pressed from the front. I mean it's the leverage of metal threads against 3D printed plastic. At some point that leverage will win but this prevents most accidents. There are also two small holes in the front of the cup to allow the long end of an allen wrench pass through to make snugging up the set screws easier.

For those interested I currently have the Dolly (48-22-8410) as the base, the Three Drawer Tool Box - 2 small $ 1 large drawer (48-22-8447) on that, the other Three Drawer Tool Box - three equal sized drawers (48-22-8443) on top of that, then two Cabinets (48-22-8445) on top of that and then one of the standard Organizers (48-22-8430) on top of it all. At some point there will also be one or more organizers hanging off of the back and a couple of the half organizers hanging off the opposite side from what you see in one of the photos. It lets me get all of my modeling hoppy tools and supplies into an 18" x 24" floor space when not in use that will roll through any doorway in my home.

Print Settings:

The 3MF files are set to use Prusa's Generic PETG profile which honestly works pretty good for most PETG filament. Aside from important settings used were:

Perimeters: 3

Solid Layers: Top: 5, Bottom: 5

Infill: Fill Density: 25%, Fill Pattern Gyroid

Supports are entirely unneeded when printed in the orientation shown.

Brim: I had an issue even on the textured plate with liquid glue where the corners would lift just a touch. Adding a Brim of 10mm solved this.

For Hardware:

Set Screws - M6-1x8mm Set Screws - https://www.amazon.com/dp/B0DY4MVNQM

Heat Press Inserts - M1 x 1.5mm L x 2mm OD Brass Heat press inserts - https://www.amazon.com/dp/B0CTCR52KZ

Rail - Aluminum 1/8" x 2" x 8' Flat Bar - https://www.homedepot.com/p/Everbilt-2-in-x-8-ft-1-8-in-Thick-Aluminum-Flat-Bar-6223/332734021

Alternate Rail (If you need more strength or the ability to use magnets on the bar) 

Steel 1/8" x 2" x 4' Flat Bar (You'd need two of these) - https://www.homedepot.com/p/Everbilt-2-in-x-4-ft-1-8-in-Thick-Plain-Steel-Flat-Bar-0717/332735531