• Initial Measurements

    William • 09/16/2021 at 05:04 • 0 comments

    I made some good progress today taking detailed measurements of the Milwaukee Packout "Compact Organizer" (48-22-8435). I need to take some additional measurements on a full-size module, such as the "Mounting Plate" (48-22-8485), before I can publish the measurements.

    I was surprised the Milwaukee Packout system has a repeating pattern which allows odd-size modules & odd attachment of them to other modules. A pair of Mounting Plates next to each-other along the X axis can be connected by a module bridging the gap between them. Latched odd pairing along the Y axis is not supported. I've crafted a socket-grid-based naming convention to easily define module sizes.

    The flanges on the repeating protrusions & sockets feature subtle "skids" to minimize surface area damage while the modules are connected. These subtle "skid" features will be difficult to replicate.

    Milwaukee designers are big fans of angles. The sockets have 45 degree champfers. The flanges also have 45 degree leading edges. These design features have some mechanical advantages & also help keep the gear "on brand." Making gear compatible with this system will require close attention to detail when making sockets & protrusions. It seems best to use strong laser-cuttable material for the upper "face" of each module. If no laser cutter is available, a drill & jig/scroll saw will suffice. The upper "face" can be affixed to another similarly-cut thicker material that will give depth to the set of sockets. Finally, those two sheets of material can be affixed to a thin "base" or "lid" for the module if the module will contain parts. The protrusions can use a similar approach: stacking about three precisely-cut layers of material to replicate the shape of Milwaukee's Packout protrusion design.

    The protruding latch can be replicated with a simple off-the-shelf "Window Bolt" or "Door/Drawer Utility Lock." Milwaukee Packout modules use a recessed slug of plastic with a pair of springs keeping it in the extended position. That spring-loaded design should be replicated when possible.

    Near-term, I plan to hand-make a few modules to confirm my measurements & conclusions are accurate. Longer-term, I will focus on simple 3D models & laser cutter patterns. This is gonna be fun!