Festool Plug-It Adapter Conversion

This design will allow you to adapt any corded power tool, allowing it to be used with the Festool Plug-It power cord system. 

This was designed so that it can be printed with no supports needed, and I specifically wanted the main body to be one piece instead of two halves. As shown in the animation below, the Festool replacement part # 489742 gets secured into the housing (once it's attached to the power cord using your method of choice) with two #6-32 x ½'' machine screws, the end cap gets attached with three #6-32 x ½'' machine screws, which pushes the two wedge shaped pieces inwards crimping them around and securing the power cord in place.

As each tool is different on the inside you may have to differ in how you attach this adapter to the tool. I designed this so the original strain relief from the tool fits nicely into the end cap of the adapter. I have uploaded a flat version of the end cap as well, in-case that may be preferable in certain cases.

Below I have uploaded photos showing how I implemented this adapter into my Bosch Jig saw. The photos should give you a good idea of the processes involved, but you will need to adapt it to your specific tool/situation.

Parts required in addition to the printed parts:

• Five #6-32 x ½'' machine screws
• Festool replacement socket part #489742
• Wire crimps or Solder 

Printing:

• PETG
• .2mm layer height
• 6 walls
• 50% infill
• no supports 
• print main body standing upright with the wider end on the print bed