Making a router fit in a different tool case

[jeffberk]

I'm trying to reuse a Bosch router case to fit an old Craftsman router. The Craftsman almost fits. The picture shows the Craftsman router almost fitting. The area marked with the green square is what I think is causing the greatest obstruction.

In the past, I've adapted cases by cutting out parts of the molded interior but here, I'd like to try something less obviously destructive. Has anyone tried heating the interior with a heat gun to soften it and closing the case on the tool to try and mold the case to fit the new tool?

 

[mogandave]

Never tried it, let us know how it works.

 

[The Cobbler]

not sure if that type of plastic will heat & bend as you hope for. as above, try it & keep us posted .
I just use an oscillating tool and cut out what I need gone when repurposing them

 

[jeffberk]

It looks like HDPE will bend when heated to around 350F so I was thinking of using a heat gun and maybe a temperature IR gun to monitor the temperature.
After reaching the point of softening, I would close the case on the router and hopefully have the case remolded to the proper shape.

 

[4xdog]

That case was blow molded originally, so it's certainly a thermoplastic (likely HDPE as you note) with some "strength" to the melt. I'd say if you're careful the idea to re-form that interfering spot should work out OK. Don't poke it with too pointy a tool.

 

[mogandave]

Lay a sheet of baking paper over the router before you close the case.

You might want to block the area you do not want to heat with foil covered cardboard.

 

[neophyte]

Sorry to gripe, but this is the reason I have always hated this style of molded case.

 

[mogandave]

Sorry to gripe, but this is the reason I have always hated this style of molded case.

But the price is right!

What bugs me most about them is that you can never seem to be able to put anything extra in.

And when you cut a hole into them whatever extra you want to carry gets stuck inside.

 

[neophyte]

But the price is right!

What bugs me most about them is that you can never seem to be able to put anything extra in.

And when you cut a hole into them whatever extra you want to carry gets stuck inside.

I actually had yo purchase extra cases occasionally back when both steel and molded plastic cases were routinely options and sold separately as a part.
The steel cases were rarely that much more expensive than the plastic cases, and had way more room for accessories, and the tool cord.
The only plastic cases that had decent room were the Festool Systainers, and that was because the cases were just general purpose, with a molded foam or plastic insert to hold the tool in place inside and some accessories.
However, Festoon started trying to fit tools in the smallest Systainer cases possible, requiring the purchase of a larger case to fit standard accessories, and it got a bit annoying.

 

[jeffberk]

A bit of a back story to this is that I'm helping out someone I met on line in Brazil. I sold him a tool last year and he approached me about accepting items he purchased from sellers that will not ship internationally. I act as a relay to ship to him and he pays me my expenses. It gives me something to do during semi-retirement. He purchased a Craftsman full size and a Bosch trim router and a case. The trim router is no problem but the Craftsman almost fits.

Apparently, the supply chain issues in the US pale with those in Brazil. My last shipment was stuck in Peru for two weeks (they are experiencing wide reaching protests), my previous shipment was held hostage by customs on his end, and my shipping facilitator warned me about piracy issues in that part of South America.

I'm going to try your suggestions out on one of my cases first. My personal preference is to use tool bags to eliminate this fitment issue. I then attach laminated tags on the zippers so I can tell them apart.

 

[yatg]

What bugs me most about them is that you can never seem to be able to put anything extra in.

Hell, most of the time the original tool doesn't fit back in unless you repack the cord just right.

 

[jeffberk]

Another reason to go with tool bags or cordless.

 

[RTM]

Lay a sheet of baking paper over the router before you close the case.

You might want to block the area you do not want to heat with foil covered cardboard.

You might want to push it into a general shape by hand before you put the router into the case. Get it 90% reversed and in a curve, so there is less likelihood of the project going sideways when you put the router in place.

 

[jeffberk]

OK, it worked. I used a piece of parchment baking paper at first as suggested but ended up not needing it. The plastic became soft and I molded it with a pair of leather gloves, reheated it and then closed the case on the router, latched the case and put some weight on it. The router now fits fine.

 

[mogandave]

Good news that!

 

[4xdog]

Show us some pix of the final result, @jeffberk. It would be interesting to see.

 

[jeffberk]

I marked the two areas that were modified. It could use a little more remolding to allow the case to close easier, but it's fine for now.

 

[mogandave]

Came out nice.

Does the old Bosch still fit?

 

[jeffberk]

Came out nice.

Does the old Bosch still fit?

Thanks...
The case was purchased separately to hold the Craftsman. I do own a Bosch with a case but the two Bosch cases are different.
If you consider that I pushed the plastic in, I've added space so the router that originally fit the case likely still fits, just a little looser.

 

[PBCampbell]

Nice job and a bit of genius.