Thread: Dangerous Kapex

OK! I finally found the problem. Its obviously a design flaw. The plastic safety guard (PSG) raises and lowers via a 2 piece bail-arm joined with a flat-headed rivet at the pivot point. This rivet head doesn't clear the rear of the PSG because the plastic protusion on the back of the PSG is about 5mm too long. I filed the protrusion gradually until the PSG returned smoothly. The amount filed ended up being 5mm (see photo **NOTE** I pushed the guard slightly to the left so I could photograph it). Now the PSG works perfectly as it should have in the first place. I haven't contacted Festool but if the their QA people are any good at their jobs they should have it fixed on the more recent versions of the machine. Or maybe Anthony can give them a buzz. Hope this helps others with the same problem.
Attachment 128691
Cheers
Sheddy in the Shed

Thanks Shed for keeping all up to speed on this ,I'm glad to see that you've sorted the issue out and can get back to making dust

Hopefully Festool will take heed of your issue that you had and take the appropriate action.

Cheers

The problem is certainly of interest to all users - has anyone contacted Festool?

soth

hi shedhand.

i have read about all the issues with the kapex and have even rectified the bulging clearance plate on my own kapex.
but your issue is a new one and i am glad to see you fixed the problem.

you should join the festoolownersgroup.com forum and post this thread and the problems you have been dealing with.
you can be confident that festool germany will be looking at this issue within a few days as they monitor the fog forum on a weekly basis.

i dont think there is anyone from festool australia that monitor this website. so the fog forum would be the best place to post.

regards, justin.

Originally Posted by justinmcf

hi shedhand.

i have read about all the issues with the kapex and have even rectified the bulging clearance plate on my own kapex.
but your issue is a new one and i am glad to see you fixed the problem.

you should join the festoolownersgroup.com forum and post this thread and the problems you have been dealing with.
you can be confident that festool germany will be looking at this issue within a few days as they monitor the fog forum on a weekly basis.

i dont think there is anyone from festool australia that monitor this website. so the fog forum would be the best place to post.

regards, justin.

Hey guys, all good with the Kapex. Anthony from Ideal Tools took it up with Festool (off his own bat) for me and they are doing all the right things about it. Shipping to melb and return, repair, investigation of issue etc. Just glad that Festool are living up to the quality of their machines.
Cheers
Mike

UPDATE
Have posted on the FOG.

Kapex plastic blade guard design fault and fix

Cheers
Sheddie in the Shed

Originally Posted by Shedhand

UPDATE
Have posted on the FOG.

Kapex plastic blade guard design fault and fix

Cheers
Sheddie in the Shed

HAHAHA! This is what I received from the FOG after the aforementioned post.

QUOTE:First, welcome to the forum. I see that this is your first post. While I know your post was done with good intentions, we have guidelines for forum members and one of those guidelines is not to post information that could be unsafe.

The modification of a tool, specifically the safety equipment on a tool, could lead to personal injury. I have removed your post for that reason. While I can't speak on behalf of Festool Australia, I know that in the U.S. we work very hard to help customers resolve issues. And, if this was a design flaw we would have come up with a solution to address the problem.

Again, I know your intentions were good but please refrain in the future from posting anything that could be deemed unsafe. Here's a link to our guidelines if you would like to read over them. UNQUOTE

This was my response to the FOG Administrator - Shane Holland (a Festool employee).

Shane, my modification made a clearly inherently unsafe design fault, safe. It would have been better to remove the mod details and leave the rest as a warning to other Kapex users if my posting of the mod contravened FOG Guidelines. I guess the guidelines have been designed to counter the ridiculously litigious society in which US citizens live. In this country, forewarned is forearmed. Thanks for the notification.
Mike

hi shedhand, i would have done the same thing as you. i would have worked out what the problem was, and then tried to fix it myself.

however, i also agree with shane holland. the best way to resolve the problem (and not void our 1+2 warranties) would be to contact festool and let them fix the problem.

as we all know, the u.s. is notorious for litigation, so i wont even bother talking any more about that.

the festool service in the u.s. is amazing from what i have learnt from the forum. so i am sure now that you have posted on the fog, they will be keeping a very close eye on this problem. good onya for posting.

btw, my own experience with festool service in australia has also been amazing, and they have always gone that extra mile for me. another great reason to support this fantastic company.

i wish we had a festool rep here on this forum. does anybody know why we dont?

regards, justin.

I agree Sheddy, I too would have on at least one occasion assumed that the blade guard was doing its job as i reached for something (although I don't have a Kapex). This is scary stuff. Thank you for bringing this to our attention and it is a clear message to all Kapex owners and potential Kapex owners that the tool may need some extra maintenance/modification to run safely in future.

It would be even better if Festool arose from their posteriors and did a recall to fix the problem or at least published a technical bulletin on the issue. What will it take to do this Festool, a lawsuit from a seriously injured wood worker?

Originally Posted by Shedhand

UPDATE
Have posted on the FOG.

Kapex plastic blade guard design fault and fix

Cheers
Sheddie in the Shed

That's great news - I now worry about everyone else who hasn't returned theirs. As I said in the previous post, nothing less than a product recall will make all Kapex machines safe.

Originally Posted by TP1

That's great news - I now worry about everyone else who hasn't returned theirs. As I said in the previous post, nothing less than a product recall will make all Kapex machines safe.

I'm wondering with all the Kapex out there in the community why this issue has'nt been at the forefront until Sheddie raised it.

There are a lot of members here with Kapex that must be in constant use with seemingly no issue.

Personally I have not had any problems to date with the kapex.

Cheers

Originally Posted by John Saxton

I'm wondering with all the Kapex out there in the community why this issue has'nt been at the forefront until Sheddie raised it.

There are a lot of members here with Kapex that must be in constant use with seemingly no issue.

Personally I have not had any problems to date with the kapex.

Cheers

Hi John, my problem may have been a result of the sustained heavy use of my Kapex. I had been using it daily for many hours. I'm sure Festool will identify WHY it happened. It may be something as simple as the rivet at the bail arm joint or the metal used for the PSG bail-arm itself needs to be a higher strength (less prone to wear with high usage) steel. Remember this bail-arm operates with every cut made so wear could be an issue unless the machine is only used lightly. I couldn't (and wouldn't) bugger around with the bail-arm in case I changed its operational geometry but filing the bit of plastic down made it work again without impacting negatively on its safe operation. I've written again to Shane Holland at FOG explaing this and he has re-posted my post (albeit edited to remove details of my mod).
Cheers
Mike

Originally Posted by justinmcf

hi shedhand, i would have done the same thing as you. i would have worked out what the problem was, and then tried to fix it myself.

however, i also agree with shane holland. the best way to resolve the problem (and not void our 1+2 warranties) would be to contact festool and let them fix the problem.

as we all know, the u.s. is notorious for litigation, so i wont even bother talking any more about that.

the festool service in the u.s. is amazing from what i have learnt from the forum. so i am sure now that you have posted on the fog, they will be keeping a very close eye on this problem. good onya for posting.

btw, my own experience with festool service in australia has also been amazing, and they have always gone that extra mile for me. another great reason to support this fantastic company.

i wish we had a festool rep here on this forum. does anybody know why we dont?

regards, justin.

Hi Justin, I think the nearest we have to a Festool rep on this forum is Anthony at Ideal Tools. This guy goes out of his way to help with Festool issues in my experience, even from people like me who don't buy Festool from him (that's changed now from my perspective). Our private exchanges on this issue have not been posted on the forum but I assure you he has been very helpful to me. I wasn't aware that FOG was a FESTOOL USA administered forum until Shane Holland (FESTOOL USA e-Commerce Manager) responded to my post by removing it. A great way to remain connected to their customer base.
Cheers
Mike

i agree with everything you have said shedhand. anthony is the nearest thing we have to a festool rep on this forum. btw anthony, sorry to call you a "thing" mate!

but i think it would be in festool australia's best interests to keep up to date with feedback from their customers. it can only work to their advantage to be aware of problems arising in some of their tools....

come on festool, we only want you to say g'day!

regards, justin.