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Thread: Warped Kapex

  1. 25th July 2021, 03:11 PM #1
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    Default Warped Kapex

    During our long, involved owner-builder project I have been using the Kapex with great results. I have almost always used the left fence, and when I used the right side it was only on narrow stock. No problem.

    But now I have to cut some 270 wide trim…lots of it, and discovered that I cannot get my saw to cut square on both sides of the blade. I can adjust it to cut square on either side, but not both. So, I put my precision machinist's straightedge on the saw and discovered that the fences dive in toward the blade on both sides by about 0.3 mm. You can see the feeler gauge I used…0.018”.

    I did some reading and discovered that this was a not uncommon problem when my saw was built. And perhaps subsequently.

    I am wondering if anyone here has any ideas about getting those fences straight and coplanar? I am trying to avoid making sub fences because I really need the full cutting capacity of the saw.

    Thanks48A06274-7F97-4E51-B671-12063FDDFA36.jpg902FC937-FD4A-47B1-900D-B711DFF79EE6.jpg

    The error means that if I calibrate the saw to be square on one side, a full width cut on the opposite side ends up being .8mm out of square.
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  3. 25th July 2021, 03:29 PM #2
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    Actually…never mind. I just did some more investigation and discovered that the fence is one aluminium casting, fairly lightweight, secured by four M8 shcs fasteners. I unbolted mine and persuaded it to return to spec with a bit of hand pressure. Checked it against the straightedge and re-installed.

    And now its within a hair of light on both sides over 270mm.

    Festool really should have dowelled that assembly in place rather than relying on bolts as a locating element.
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  4. 25th July 2021, 08:56 PM #3
    riverbuilder
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    They will send you a new one if you make enough noise about it, a couple of guys I know got theirs replaced
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  5. 25th July 2021, 09:03 PM #4
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    Mine is probably 10 years old by now so I would be surprised. The problem is the bolt holes in the casting have enough slop in them to allow the fences to get knocked askew during construction use. I find tool calibration to fall under routine commissioning chores, but can’t excuse such a basic flaw in such an expensive saw.
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  6. 25th July 2021, 10:11 PM #5
    riverbuilder
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    The bolt holes are elongated for adjustment purposes actually, it’s not a manufacturing flaw.
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  7. 26th July 2021, 01:44 AM #6
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    So I actually had a dream about this and realise that dowelling what looks like a die-cast part wouldn’t be practical for a couple of reasons. I get that a bit of adjustment slop is useful for set up, but it does make it possible to lose the reference surface. I have learned my lesson and will check the alignment more frequently
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