DF500 Domino face alignment issues

[LDBecker]

This short video illustrates what might be the problem:

This ^^^^^ if the fence did slip due to insufficient purchase. The OEM handle is so well designed to allow for any necessary adjustments.

Oh Good Grief - I've been fighting with this the whole time I've had the DF 500- over 10 years. I had messed up the gears that allowed for the mortise size change, and when Festool repaired it (for free, I might add, even after the warranty was expired), it came back with one side of every mortise about 3/128th higher than the other side, so the mortise wasn't horizontal. Compound that with the second mortise, and you get a noticeable mismatch in parts. I had cranked that lever down as much as possible, but it jams up against the body of the Domino and never seemed fully tight. I guess it wasn't, and it messed up my mortises so much that I resorted to a Kreg Jig (GASP! DIOS MIO!) to build some cabinet face frames for my kitchen. It was discouraging... I finally have time to finish the project (post COVID, job change, etc) and I was determined to figure it out. I even wrote to Festool tonight to see what they had to say... Then I saw this video. The parts are ordered... For now, I'll make sure it's all on a flat surface, push the fence down and crank it as much as possible with the current handle. Thanks for putting this up here!

 

[jeffinsgf]

Nothing wrong with getting the ratcheting knobs, but the factory knobs can be adjusted in nearly the same way. Just remove the screw holding the handle, adjust the handle back one or two clicks and replace the screw. It's exactly the same style handle minus the ratcheting mechanism. When you get it clocked correctly, it's less fiddly than the ratcheting knob.

 

[LDBecker]

Yes, I'm seeing that ability to adjust the factory knobs now. What's weird is that I'm not really sure that was my problem. The slot that the DF500 cut was elevated on the side of that knob by about 2 or 3/128th of an inch consistently. I finally got it to cut a level slot by very deliberately forcing that side down as I tighten the knob. I never really noticed this before - just thought the thing was out of alignment somehow.
While I was at it, I re-calibrated the plastic center line fence on it as well. I'm happy with the way it's cutting now.

 

[Birdhunter]

My 700 cut a slanted mortise. I sent it in for adjustment along with an example of the slanted mortise. It came back adjusted with a perfect mortise the tech had cut. I also think the bit in both the 500 and 700 can "climb" during the cut.

 

[Crazyraceguy]

My 700 cut a slanted mortise. I sent it in for adjustment along with an example of the slanted mortise. It came back adjusted with a perfect mortise the tech had cut. I also think the bit in both the 500 and 700 can "climb" during the cut.

I think you are right, to some degree, anyway. I have seen people plunge a bit "aggressively" and have no doubt that it could cause some kind of movement. End grain in especially hard wood probably being a good candidate.