DF500 Connector Blow Out

[Df1k1]

So I recently purchased the DF 500 connector set and I have been really really happy with it. Have been building some closet organizers and everything was going along great and then all the sudden a couple pieces suffered from blowout when I drilled for the connectors. None of my measurements have changed, I’m  referencing the same face etc with the Seneca Domiplate.  All melamine is the same size close to 19 MM.
pretty bummed and I can’t figure it out. Watched a ton of videos and I don’t believe I’m doing anything wrong. any ideas?
UPDATE
So I went out there and looked and realize the mortise is clearly off. But for the life of me I can’t figure out why that would occur. I’m using the Seneca as a fixed reference why would that mortise have been so low? Wondering if the Seneca is not the choice to use with the connector system.

 

[Imemiter]

Is the plate set up to center on 1/2"?  Also, I'm a noob to the Domino way, but I'd consider using a smaller cutter here.

 

[RustE]

Can’t use a smaller cutter with the connectors.  Kind of looks like the DF500 got tweaked a bit as the plunge was made?

 

[MaineShop]

I find in particle board I have to feed slower with the domino since itt wants to chatter more in the cut. Makes it a little harder to keep the cut straight for some reason compared to hardwood. Your milage may vary.

 

[Cheese]

Check the 8 mm cutter to make sure it's sharp and doesn't have any chips or missing pieces/tips. It looks like the Domino decided to find its own center for some reason.

 

[Df1k1]

Thanks all. Cutter is fine. It must’ve an operator error. Somehow I twisted it that’s the only thing I can think of. For what it’s worth still a big fan of these connectors. Especially with things like closet organizers and melamine. Way too heavy for one guy to maneuver out of the shop and into the closet.

 

[Df1k1]

Is the plate set up to center on 1/2"?  Also, I'm a noob to the Domino way, but I'd consider using a smaller cutter here.

As noted you cannot use a different cutter. And if using Seneca plate you can’t adjust where the mortise sets up

 

[RustE]

...
And if using Seneca plate you can’t adjust where the mortise sets up

I’m guessing the 3/4” version?

Seneca has an offset shim pack; although in metric for the 12mm and 18mm Domiplate.

 

[Imemiter]

As noted you cannot use a different cutter. And if using Seneca plate you can’t adjust where the mortise sets up

I meant that it looked like he had it flipped over to the 1/2" side. But here again, I don't have a Seneca plate yet tho' that appears to be the way they work.

 

[ChuckM]

I, too, thought that the Dominoplate was used with the 1/2" registration face rather than the 3/4".

But after seeing the OP's image, I was surprised that the two mortises were not distanced the same from the board's surface. It's  likely that the wrong side of the plate (1/2") was used and user error was also committed plunging.

 

[Birdhunter]

When this happens to me while cutting mortises, it’s always my error. Sometimes, I don’t have the fence tight enough and it creeps. Sometimes, the cutter “climbs” if I drill too fast. The cutter develops torque as it cuts into the material. It’s like a router bit on a climb cut. Unless the bad mortise repeats, the error is mine. My 700 developed a tilted mortise problem. festool service readjusted the unit and fixed the problem.

 

[Df1k1]

When this happens to me while cutting mortises, it’s always my error. Sometimes, I don’t have the fence tight enough and it creeps. Sometimes, the cutter “climbs” if I drill too fast. The cutter develops torque as it cuts into the material. It’s like a router bit on a climb cut. Unless the bad mortise repeats, the error is mine. My 700 developed a tilted mortise problem. festool service readjusted the unit and fixed the problem.

Hey guys definitely the Seneca set at the 3/4. Have never used it another way. I just think I was sloppy all in all.  I can’t  explain why one mortise  would still be so much lower than the other but I just have to believe it must’ve been an operator error. I’m not a professional and I still find the domino to be a funky machine. I don’t reach for it a lot of times because I never seem to have the awesome experience  everyone else does.  But in reading all the comments and thinking the way I use it I think I need to start using it more and become more confident and familiar with it

 

[Cheese]

I don’t reach for it a lot of times because I never seem to have the awesome experience  everyone else does.  But in reading all the comments and thinking the way I use it I think I need to start using it more and become more confident and familiar with it

The best advice I can give you is to be very careful when first pushing the bit into the wood, take it slow and smooth. Any rapid movements are a certain disaster. Remember, the cutter is rotating at 25,500 rpm and it's also moving from side to side. If the cutter tip or an edge grabs the wood suddenly it's going to go where it wants to go and it can give results like you've illustrated.

Practice is a good thing.  [smile]

 

[Birdhunter]

Cheese is giving excellent advice. Also,I use the Festool connectors with the 500 and the 700machines. I have the Seneca accessorize (fine products) but I don’t use the with the connectors.

I’ve never tried putting the connectors into anything but solid wood. is the composite  board strong enough?

 

[Df1k1]

Cheese is giving excellent advice. Also,I use the Festool connectors with the 500 and the 700machines. I have the Seneca accessorize (fine products) but I don’t use the with the connectors.

I’ve never tried putting the connectors into anything but solid wood. is the composite  board strong enough?

Cheese always does!  And yes the particle board really grabs the connectors but definitely not as much as solid wood. But in the particle board they’re really strong

 

[Crazyraceguy]

It looks like simple operator error. With a solid plate, like the Senica, it can't drift down. So, either the cutter is climbing in the initial plunge or the machine is just not registered properly against the board before plunging. You don't have to move in a way that would actually be called "slow", but you do have to allow the cutter to cut. There is a bit of "feel" to it, but it's not rocket science either.
You are using some kind of dust extraction? right? The Domino is not at all forgiving about that.