ECS Bay Tool Containment Device

I work on F-15 fighter jets as an Electrical Operator. My work involves routing wiring bundles and building connector plugs during the splice of the forward, center, and aft of the jet. In the FWD CNR splice area, I spend a lot of time in the ECS (Environmental Systems Control) bay of the jet. The operator is lifted into the belly of the jet by scissor lift into the confided space of the ECS bay. On a daily basis I must bring pliers, screwdrivers, side cutters, gloves, different sized sockets, ratchets, wrenches, nut runners, screws, washers, and nuts into the bay. It becomes difficult in the confined space to keep track of tools and increases the probability of FOD (foreign object debris). The ECS bay has a blank wall on the Center bulkhead where I built and will attach my tool containment device.

Materials:

• 11”L x 6”H x 2.75”W Container

• 11”L x 3”H x 2.75”W Container

• Circular 3” diameter magnets, quantity: 2

• 2” x 16” magnetic bar

• 16 gage punched flat bars 1-3/8” x 48, quantity: 2

• 2" diameter PBC pipe

• Sheet Metal

• Washers, quantity: 8

• 7/16" dome head fasteners, quantity: 8

• Nut, quantity: 8

• 1/4" foam

Tools:

• Drill

• 1/4" drill bit

• Cut off wheel

• Bandsaw

• Flat head screw driver

• Wrench

• Epoxy adhesive

After I had a rough idea of what I wanted my tool containment device to be, I took measurements of the bulkhead that the device will hand on.

After measuring where the containers will be placed on the rails, I drilled holes in containers to attach.

I used a vice to bend my rails. I put two 90 degree bends in the rails in order for it to hang from the top of the bulk head. I then cut off the excess material.

I ordered a 16" magnetic plate so I wanted to cut it to match the dimensions of my containers. I cut a small piece of sheet metal to put a patch over the cut side of the plate. I utilized as many magnets as I could because it makes for easy access to pan stock and tools. There are many times when I'll be holding up a heavy bundle and I need to quickly reach for a bolt and nut runner to install my clamped bundle to the structure. Magnets make this very easy.

I use lots of zip ties while routing wire bundles and wanted to have a separate container for easier excess. I took a 2" diameter PBC pipe and cut the length to 11". I cut off part of the side of the cylinder in order to have some surface area to attach it to the rest of the device. After I cut off the side, I attached and cut sheet metal to cover the side. Next, I bent over the excess material and trimmed a circle so the cylinder had a bottom. I then used the adhesive to attach the metal to the PBC pipe.

I attached the container to my rails with a screw, nut and a washer under the head of the screw and nut. I attached the lager container with 4 fasteners and the smaller container with 2 fasteners. Next, I attached both circular magnets with the same fastener stack-up. Then, I used the epoxy adhesive to attach the magnetic plate and the cylinder. I then cut my foam the same size as my rails and attached it with the adhesive. I need foam on the back of my rails in order to protect the bulkhead from any damage or scratches form the metal rails.

This device makes my job so much easier and it can be used for many things in different situations. Of course there are different ways that it could be built and different materials that could be used. I selected my design and materials based of the constraints of the area I work in. I already had the hardware and tools I needed so all in all I spent about 68$