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Author Topic: DF500 breaking cutters  (Read 2153 times)

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Offline kevkrieg

  • Posts: 7
DF500 breaking cutters
« on: April 11, 2019, 08:06 PM »
I have a DF500 and everything was working fine, then earlier this week I broke a 5 mm cutter on some white oak.  I bought another one and within 15 cuts it broke the tip too.  Festool is standing behind the cutters, so that is good, but then today I was using it again with a 10 mm CMT cutter and it broke the tip off too in popular, so very soft wood.  I'm plunging it slow and smooth.  After the 10 mm broke I noticed a small screw on my workbench that looks like this...  Any ideas on the issue?  Thanks. [/img]

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Offline Cheese

  • Posts: 6454
Re: DF500 breaking cutters
« Reply #1 on: April 11, 2019, 08:37 PM »
There have been previous threads on the FOG about breaking #4 & #5 cutters. Try a search.

Personally, I've never had an issue with either size and I've used them hundreds of times in maple, oak, 2x material and even Brazilian mahogany which has a Janka hardness in the 2500 range. I think that is roughly twice the hardness of hard maple.

I just put in 160 mortices today with a Festool #6 cutter in BB ply without an issue.

Offline Vondawg

  • Posts: 285
Re: DF500 breaking cutters
« Reply #2 on: April 12, 2019, 08:27 AM »
The obvious question....you’re not plunging too hard/fast  are you ?
There are no mistakes....just new designs.

Offline Birdhunter

  • Posts: 2685
  • Woodworker, Sportsman, Retired
Re: DF500 breaking cutters
« Reply #3 on: April 12, 2019, 02:40 PM »
I looked closely at my 500 and did not see anything that looked like your mystery screw. If it came from inside your 500 it might explain the breaking bits.

I’ve cut hundreds of mortises with my 500 and I can remember breaking 1 4mm bit and 1 5mm bit. I mostly use very hard exotic woods.

Entering the wood gently and progressing smoothly makes the bits last longer. I use my body and not my arms to move the 500. It’s the same feel as using a hand plane.

Offline jobsworth

  • Posts: 5838
  • Festool Baby.....
Re: DF500 breaking cutters
« Reply #4 on: April 13, 2019, 10:33 AM »
Ive had my 500 for a few years now and have not broken a bit.

 The first thing that comes to mind is incorrect technique, plunging rate, holding the 500 square to the material, aybe fence adjustment etc etc.

Could also be the OP just got a bad one. Sometimes that happens to.

Offline MueMi

  • Posts: 8
Re: DF500 breaking cutters
« Reply #5 on: April 27, 2019, 03:04 AM »

could it be probably part no. 20?

« Last Edit: April 27, 2019, 01:29 PM by MueMi »