Custom Plasterer Van Racking: ToughSystem + TSTAK Combo | Custom Solutions UK

Tailored ToughSystem and TSTAK storage with full tool access, custom drawer heights, and integrated scaffold board trim — all built in premium birch ply.

Find the original build here we then made all the changes below and come up with a new install this can be found [LINK] ill update this shortly, we are now adding this to our site.

BEFORE

AFTER

When Chris, a local plasterer, reached out to us via WhatsApp with a detailed vision for his Renault Trafic SWB (67 plate), we knew we had an opportunity to push the limits of what a full custom van install could look like. Starting with some simple diagrams we knew we could fix this storage issue.

📦 Unit 1: TStack Unit with Nail Guns

Unit one ended up as unit 2 when fitting, some parts were moved around in the installation process again this is a factor with a modular design.

The first unit is a full-width tstack units at 474mm designed to house:

2 x Paslode nail guns in orange cases
Small parts tray

This section maximised the user’s tool access while locking each item into place securely for transit.

💡 We also made a key design decision here: spacing the unit to suit the customer’s specific gear rather than a fixed shelf system. This allows perfect fit but limits flexibility for future reconfiguration.

⚙️ Unit 2: Chop Saw + TSTAK Screw Boxes

Unit 2 ended up as unit one in the install

Next, we created a slide-in/out base for the plasterer’s chop saw:

Width: 460mm
Height: 370mm
Fit: Tight, but accessible
One TSTAK 300s

Above the saw, we added 4 x TSTAK boxes, including:

A TSTAK drawer (approx. 175mm) and two smaller screw box trays
All housed in a 120SP-compatible unit, ensuring the drawer rails aligned properly

🔊 Unit 3: Radio + Medium Drawer

A compact unit tailored for:

Radio (W: 180mm, H: 240mm, D: 250mm)
Charger box (Tough 2.0)
One medium drawer for bags, tapes, and accessories

We set the drawer at a height that balanced access and stacking space without wasting vertical clearance. With a tight centre divide to allow flexibility in rotating the charger box (approx. 230–270mm depending on orientation).

🧴 Unit 4: Dewalt ToughSystem, PVA, Tilt Storage + Optional Drawers Added.

Final unit included:

5L PVA tub in tilt storage in front of wheel arches
2 x Dewalt ToughSystem boxes (stacked)
2 x custom Drawers to fufill the space for skrim tape

Spacing in this unit was custom tweaked during the workshop visit to support future upgrades, including potential dual ToughSystem drawer stacks.

We designed the unit to a tought system box size of 534mm width and 620mm height. We left the hight as 630mm and a over all init width of 600 externally with a internal of 576mm.

Check out the custom Hawk holders, we will happily make these to any size just screw them on and slide the Hawk away. Ill update you with a purchase link. remember to add the Hawk sizes at check out.

🪵 Scaffold Board Trim, Upstand + Levels

We replaced the scaffold board at the bottom with the following, we originally had the board planned to go at the bottom.

Ox levels box underneath (1.8m and 1.2m levels)
20mm x 12mm trim (used on top to divided speed skims)
2 x Speed Skims (920mm) and storage for offcuts
Front upstand trim for neatness and strength (not yet added in photo)

This made the rear storage safe and functional — without sacrificing height access.

🪜 Ladder + Hop-Up Storage

On the side, we mounted:

Werner yellow ladders (1270mm length, 370mm x 200mm profile) These eneded up being placed closer to the bulk head to save room.
Hop-up (200–230mm height, 690mm length, 400mm depth)
Custom 1200mm Rail, Darbey, or Level box.

These were positioned near the left wheel arch to balance space and load access. Leaving middle access as a max for 25kgs bagged materials.

🔧 Final Modifications — Made in Workshop

After the WhatsApp planning stage, the customer visited our workshop to finalise key changes:

Custom level box added under the right-hand side
1200mm custom box created for plastering tools and straight edges
Trestle storage moved to the left wheel arch for accessibility
Two custom drawers added to unit 4 based on new vertical allowances. These were also made a custom height.

These adaptations reflect our ability to adjust on the fly — but we always explain the trade-offs. where the 2 custom drawers now are the groove spacing has changed this then limits the system as a system. but it maximised what the customer asked for. this was a ultimate trade off that we explained to the customer.

During in this install there were changes still made and will be continually made this is the benefit of the system. Multiple items can be housed in multiple locations. so then new tool always fits. Some of the locations above might be seen as inaccurate but it was down to the customers final layout Chris decided on. We understand that any of our installs can suit multiple trades wether you are a Carpenter, Plumber, Decorator, or Plasterer.

🧠 Understanding Custom vs Systemised Installs

This install worked beautifully for the customer's current workflow. But custom spacing means:

You get exactly what you need today ✅
Future reconfigurations are slightly limited ❗

That’s why we’re clear with our clients: custom installs suit specific use cases, while systemised setups like ours out the box (with standard spacing suits drawers or trays with height of 44mm, 108mm, 172mm or custom offer more flexibility for upgrades later on.

We have built an adjustable system out the box to suit most tool brands. the closer a customer works with us the more features and things we can look at. we understands no 2 install at the same so for this reason on a standatd unit we have up to 14 different otions to use for tool boxes, trays, drawers, chop saws or more. you are sure to re configure on the fly just when you need to. We built the Original All Wood Drawers System.

🔍 We help you choose the right approach based on your tools, trade, and budget. We dont build racking to suit a vehicle! all our racks fit all vehicles. We maximise the install to your budget, tools, the way you work and your future.