Customizing your Milwaukee Packout Stack with Smart Mods and Labels

About a month ago I wrote up a post about Milwaukee’s Packout system and how it’s a boon not just for traditional tool guys and gals but for DIYers as well. Back then little did I know that the amount of aftermarket customizations available for Packout products is absolutely insane. From custom drawer and bin inserts specifically made to hold certain tools perfectly, to add-on side tables and mounts, to custom labeling for every storage area, there are a lot of options depending on your needs. I’ve interacted with a dozen or so companies/folks offering these products, and there is plenty of enthusiasm driving new options and product developments.

I think perhaps my favorite of the products are the 3D printed tool trays for the Packout bins and drawers. These are primarily available for the 3-drawer boxes and make your tools look as neat and tidy as Stewie’s arsenal in Family Guy. I found that Samuel from Toolitek that operating on Etsy offered perfect fitting options that look excellent. There are options available for M12 and M18 tools and batteries, including drivers, drills, impact wrenches, detail sanders, die grinders, and other items. The trays are printed in red and black for a perfect match to your Packout gear.

Tool and battery trays from Toolitek

For the 3D printed trays that fit inside the Packout bins, I’ve had good luck with 10Spot tools. This shop offers the Jonah Pope designs for reasonable prices, as well as other options such as the smaller trays for the bins with inserts that can accommodate drill bits, Dremel discs, jigsaw blades, and other items.

If you are looking to make your Packout stack more of a work center, there is a robust amount of side mount offerings. These mods were likely not predicted by Milwaukee as you will need to turn a drill on your precious bins to temporarily remove the side-bars, but I found it was well worth the trouble. At the top of each metal side bar, there is a round plastic protrusion that secures it in place. You can use a screwdriver to try to provide enough clearance to slip it out, but people have cracked or damaged the surrounding plastic doing it this way. The better way, in my humble opinion, is to drill away this plastic and use the rail caps offered by these companies to replace it. This allows you to secure the bar with a screw instead of pressure. Should you wish to change your side configuration in the future it will also be infinitely easier to remove the bar from the case.   

Aftermarket rail caps (top) and original caps (bottom)

My selected provider for the side rail offerings is PackibleTools. They have clearly spent a lot of time and attention on their products, and while they are more expensive than others, they exude quality. The primary reason I selected Packible over other offerings is the metal rail brackets. Given the nature of 3D printing adding plastic layers one by one, it can lead the plastic to split under pressure. In addition, utilizing plastic rather than wood for the side table reduces the weight when you need to reconfigure your stack, and the “juice grooves” are handy for catching small screws before they roll off the table. If you’d prefer a wood or steel side table, Dirt Church Industries has some nice looking options, and like Packible, offers the rail caps. Also I gotta admit it's a cool company name. 

Side mounted table and mounts from Packible

Side table and mount in upright position

Now if you want to customize your Packout stack to the tilt, there are folks offering 3D printed plastic handles and latches so you can note what you have in each drawer. Etsy sellers like Chris at TaylorCustomEng, 10 Spot Tools, and CustomToolKits each offer unique options customize and enhance your stack. You can label your drawers, label the side latches, label a handle, customize the square logo, the sky is the limit. I will say that getting the metal loop off of the latches is a PITA, but it looks so good afterwards I think it’s worth the hassle.

Finally, I’ll be discussing the custom trays for the Packout bins. The trays that come stock are perfectly serviceable, but if you’d like to arrange your bits and bobs in a more organized fashion you can order custom trays that hold the standard Milwaukee Shockwave bit holders. Simply yank them out of their organizer and pop them into the bins, easy peasy lemon squeezy. These trays are available from Michael at PolymerPrintCo, 10 Spot Tools, and MWReclaimed offers a similar solution that includes the hex bit holders.

Also, a special shout out to Michael at MWReclaimed. I had purchased a battery holder tray from him designed to fit in the Packout bins. It was a very nice product, but he actually redesigned it to keep the batteries from tumbling out if you are travelling out and about with your bins and things go horizontal and he sent me the new version free of charge. It caps the batteries with a tray so you can fit even more items in your bins, a super smart design. I look forward to seeing what else he comes up with! 

MWReclaimed battery storage tray, the left tray snaps on top, awesome design

Bottom line, the sky is the limit when it comes to configurations for this storage system, so whatever your DIY hobby or profession, there is likely one that would work perfectly for you.   

More images to come in the next few weeks!

   

Modding the Sega Game Gear with McWill Screen, New Caps

The classic gaming industry seems to be enjoying the same explosion of popularity as the revitalized vinyl album market. With various catalysts such the low cost of production for small, single-board computer systems and the proliferation of cheap LCD panels, we've seen many interesting solutions hit the market in the past couple of years. Some of my favorites have been the NES and SNES Classic, the SNK Mini, the C64 Mini. Many fun new home-brew options are also now available such as 3D printed cases wrapped around Raspberry Pi boards housing thousands of classic games. Technology these days is incredible.

An example of a mini console with Raspberry Pi inside

One of the things about emulation is sometimes a game works well, and sometimes it can run a little funky. Situations like this can leave you yearning for that original hardware… back when times were simple and you could slap a big plastic cartridge in an over sized toaster-like device and everything worked perfectly. You might even dust off your old systems to see how they've held up over the decades. That’s when you realize hmmn… some have not aged as well as others.

If you showed any youngster a Sega Game Gear today, they’d think it was a piece of junk, and I suppose they’d be half right. I was a huge fan of the Sega Game Gear back in the day, and for days when you’re getting shuttled around in the family van, it was like living in the lap of luxury. Having a color screen on the go was revolutionary, and you had to save your allowance for quite a long time to get not only the Game Gear, but a $50 rechargeable battery pack to boot.

The jumbo-sized Game Gear PowerBack

Why was the battery pack necessary? That puppy would eat six AA batteries in four hours flat. It was as inefficient on juice as a Hummer is on gas. Much of that was being drawn from the 160x144 pixel color screen with back-light. Compared to LCD screens today, the screen looked like someone took several layers of Saran wrap and window tint and covered it up. Everything is faded looking and slightly blurry… and this is even on the newer, better Majesco screens.

As you can see, he doesn't like it very much

Not only is the screen lackluster by today’s standards, but the capacitors in the unit are also ready to give up the ghost. Capacitors are little tubular parts that store energy in a circuit, you’ll find plenty of them from the earliest circuits in existence to your cell phone today. Electrolytic capacitors tend to be one of the first things to die in old electronics. These are typically the first items to be replaced in most older electronics which are being refurbished, such as popular amplifiers from the 1960s. The Game Gear caps are getting to be three decades old, so they’re on the way out if they haven’t started leaking already. It doesn't help that caps during this time were especially poor quality either. If you're curious about capacitor degradation, Quora has a nice article about it.   

The innards of a typical capacitor

So what is one left to do with a poor old Game Gear that no one loves anymore? Fortunately, you have options. Many sellers on eBay will sell you a batch of capacitors to replace all the caps in your system for $5-10. They come with directions too. If you’re handy with an iron, this is a pretty easy task and will take 1-2 hours to replace them on all three internal boards (the power board and sound board are mounted separately). At the end of the day though, you’re still stuck with that crappy screen.

An example of a Game Gear Capacitor Kit from eBay seller GeekTronics

Fortunately, a gent named McWill offers a mod so that you can install a fresh new LCD screen in your game gear. It’s not a cheap mod, $120 as of this writing, but given the niche market for something like this, it seems reasonable. It also comes with a VGA output, so that’s a value-add right there. The difference of this screen is amazing… bright and crisp. Night and day compared with the old screen, and the new screen uses much less power to boot. So where’s the fly in the ointment?

McWill Game Gear mod available from Console5.com

I’m a hobbyist and I like to tinker with things and enjoy soldering PCBs with through holes parts. This, however, is not a fun mod… it’s more like work. There are minuscule SMD resistors which need to be moved/bridged and soldered to, and there are very small traces underneath, which if damaged would be difficult to find a trace on the board to fix… you’d be digging around for a schematic, and I don’t know if one is out there for the Game Gear… especially since there were 5-6 versions over the years.

My suggestion: unless you are very confident with your solder skills, I recommend you have someone else handle this mod for you. Your first time through will likely take 5-6 hours if you like to check your work, and the prices people charge on eBay for the install are a bargain (assuming they do good work, I can’t vouch for that).  

While you're in there (or someone else is), another nice cheap upgrade is replacing the stock plastic screen with a new glass one. They can be found on ebay for around $7 and offer make the image even clearer. They are flat though, compared to the bulbous plastic screens, so they change the look of the game gear slightly. The glass screens can also be installed without opening the game gear, but it is a bear to get it off and you can damage the surrounding plastic. 

On another Game Gear, I tried using the typical plastic tools to get under the lip without success. I ended up epoxying a wooden dowel to the screen which I slowly leveraged up to get the plastic screen separated from the unit. 

Below you can get a looksie at the internal mod on a Magic Knight Rayearth red Game Gear using 24-gauge silver plated copper in PTFE hookup wire.

Adjusting the white balance so you can see the screen quality better

Given the McWill Atari Lynx installation is quite similar, I wanted to include photos of that as well:

I hope you enjoyed the write-up. Please keep those wonderful handheld systems alive! 

Is Milwaukee's Packout System the DIYer's Dream Come True?

In terms of consumer products there hasn’t been much that’s really impressed me lately. The current trend has been that large corporations looking to cut costs are charging more for progressively inferior products, with the only solution being to pay a ton of money to smaller companies that still actually care about what they put on the market. While it's great to support small businesses, people generally don't have the coin to only buy well-crafted artisan products. 

Fortunately, Milwaukee, while being a large corporation, still seems to care about providing excellent performing tools that often win the various tool showdown videos on Youtube (now you know how I waste my spare time 😅). Do we all need a brand-new hammer drill with 1,400 lbs. of torque and an auto-stop feature that kills power when your wrist gets caught in that torque? No, but for those of us that do, it makes punching metal easier, and the auto-stop will be worth the money the first time it activates.

Similarly innovative is Milwaukee’s Packout system. Initially I brushed it off as a way to sell more cheap overseas plastic products to consumers. Given many Milwaukee tools are brushless I clearly made an error /dadjoke. On second glance, the Packout gear is a gamechanger for a variety of purposes, and it’s obvious why all the other brands are desperately trying to catch up.

Slim Packout tray with organization compartments

My use-case is probably outside of Milwaukee’s main audience, but it makes sense. My workroom is on an upper level, and while one of those big metal toolboxes (think Craftsman or Husky) would be really nice, getting an awkwardly sized 200lb. box up the steps is a deal breaker. The metal toolboxes also tend to pick up dings and dents on their way to the hardware store or your house which would dampen that serotonin hit when you buy a fancy new toy. Instead of a rolling metal toolbox, how about a rolling sturdy plastic one that largely works the same way and is much lighter? 

The tower of power

What if it’s modular so you can pick and choose which drawer configuration you’d like, and you can pull off a chunk of it (or all of it) and throw it in the car if need be?

Removable work surface

This is the genius of the Packout gear. It can be configured for a variety of needs and easily moved about the workroom, garage, or transported when needed. You do pay for the privilege though, as the Packout gear is priced at what I consider a premium, but it often goes on sale at Home Depot, so I’d advise waiting for a deal and using a cashback app to get a few bucks back.

Internal dividers are handy for organizing small parts

This system will definitely tickle the fancy of anyone who’s obsessive or has a touch of anal retentiveness, as Milwaukee offers some of their tools conveniently in Packout cases. The ¼” and 3/8” socket sets, hole saw sets, Shockwave bit sets, etc. that lock right into your gear stack. 

Mechanics socket set in Milwaukee brand trays

There are customizable foam inserts so you can get your tools arranged just the way you like them. More excitingly, though is there is a contingent of folks on Etsy making custom 3D printed inserts that fit your tools perfectly. If you are lucky enough to own a 3D printer there are files floating around you can print off as well.

3D printed battery tray for tool batteries

There are other modular items that pop on as well, like wet/dry vacs, coolers, work lights, etc. so it really caters to a variety of needs, so long as you can cover the cost of admission. 

Sorting my equipment knobs on the work surface

Given all the unique benefits, I think we are witnessing the next logical evolution of the garage toolbox that just so happens to be perfect for the DIYer in a workroom too.