Domino 500 issue- width switch self-turning, bit breaking

[LDBecker]

Not sure what's going on with my Domino 500. I all but gave up using it a while ago- a 5mm bit broke, ordered a new one, and within 2 cuts the new one broke. I kind of got disgusted and got busy with other things.
Now, on a new project, using a new 10mm cutter, I notice the cuts seem rough, and I ruined a cut because I didn't notice that the width switch, which was set to narrow, moved on its own to the widest setting. I thought I must have bumped it or something, reset it, and watched it happen again, moving on its own. I'm cutting into red oak handrail stock.

The cuts are ok, and the bit looks ok. What's happening???

Thanks!

 

[ear3]

Hopefully it's within the 3yr service window? Cuz this sounds like a major malfunction.

One note-supposedly one us only supposed to change the mortise width settings while the machine is runn8ng. Someone with machine knowledge can chime in as to why that's the case -- I only know that it's bad for the machine if you don't follow that protocol. Is it possible you tended to change mortise width while machine was off?

 

[LDBecker]

I don't think I changed the width setting with the machine not running, but I may have. I went back over the supplemental manual before I started this project and noted that concern.  I bet most people have, in fact, changed that switch with it off. Is that really a death sentence for the Domino 500. If so, it's far too easy to do, and not marked on the machine to avoid doing it...

Any other ideas? Anyone else possibly turned that switch with the machine off?

 

[ear3]

Yeah, I'm sure most of use have by mistake, and I would seriously doubt that a few inadvertent turns would result in catastrophic failure like you're experiencing.  Was just curious what your usage pattern was.

Sounds like a service call is in your future come Monday.

I don't think I changed the width setting with the machine not running, but I may have. I went back over the supplemental manual before I started this project and noted that concern.  I bet most people have, in fact, changed that switch with it off. Is that really a death sentence for the Domino 500. If so, it's far too easy to do, and not marked on the machine to avoid doing it...

Any other ideas? Anyone else possibly turned that switch with the machine off?

 

[atomicmike]

My recollection from classes is that it's okay to change it while the machine is off, as long as you're not forcing it. It's just strongly recommended that you have the machine running first, so you don't inadvertently cause some damage when changing widths.

 

[LDBecker]

That makes sense... I turnd it on and changed widths several times -  it seems to be functioning correctly. I am also being careful not to feed it too fast and to push from the back (so as not to change the angle while plunging), and the cuts I'm making are supported on flat stock while I'm plunging into the handrail stock with a firm hand on the front handle.

I guess I'll keep an eye on it as I finish making the ballaster assembly - probably about 16 ballasters total- this is in clear redwood, so probably not much of a test. I was just wondering if this was a common issue (I did search, but didn't find much). I'll post back when I'm done or give up in frustration.  Thanks!

 

[copcarcollector]

My recollection from classes is that it's okay to change it while the machine is off, .

On the 500, I got the opposite impression from a Festool trainer. I was told to change the widths only when the machine is on, due to the gear meshing. Changing while the machine is off can damage the tiny gears. Not sure if this applies to the OP's issues, just what I was told.

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[copcarcollector]

The OP wrote

"the width switch, which was set to narrow, moved on its own to the widest setting. I thought I must have bumped it or something, reset it, and watched it happen again, moving on its own"

I think it's time to contact service on this issue!

 

[sancho57]

I concur with Jeff (copcarcollector). I have not moved any switch debth or width w/o the machine turned on and I have not had any issues with the tool other then operator error.

A quick call to festool service or depending on you dealer, a quick trip to the dealer with the tool will be very helpful.

Since your in LA and I don't know exactly where, Austin Hardwoods in Santa Ana, Anderson Plywood in LA, Aldo at In touch tools Palm Springs, Woodcraft Orange County are all very good sources for info and buying festoons.

If any are close to you they all have festool trained folks there who can help you even if you didn't purchase it from them. They are pretty good people.

 

[bobfog]

Have to admit I never read that part of the manual, nor recall ever seeing it on any Youtube videos I watched when considering the purchase of the Domino 500.

I almost always use the tool on the tight setting and so have only moved the width adjuster a few times, so hope I haven't done any damage by moving when the machine is off.

I have to admit this whole thing of adjusting it while running is a bit counterintuitive. My brain is conditioned with almost every other machine/tool I've used, where trying to change speed/gear would more than likely cause serious damage if the motor was running. 

 

[Brice Burrell]

My recollection from classes is that it's okay to change it while the machine is off, .

On the 500, I got the opposite impression from a Festool trainer. I was told to change the widths only when the machine is on, due to the gear meshing. Changing while the machine is off can damage the tiny gears. Not sure if this applies to the OP's issues, just what I was told.

I have been to Festool classes numerous times, atomicmike's recollection is correct.  As long as the knob isn't forced you'll be fine.  Still, I'd call Festool and see what they have to say about the setting changing on its own, that just doesn't sound right to me. 

 

[LDBecker]

I concur with Jeff (copcarcollector). I have not moved any switch debth or width w/o the machine turned on and I have not had any issues with the tool other then operator error.

A quick call to festool service or depending on you dealer, a quick trip to the dealer with the tool will be very helpful.

Since your in LA and I don't know exactly where, Austin Hardwoods in Santa Ana, Anderson Plywood in LA, Aldo at In touch tools Palm Springs, Woodcraft Orange County are all very good sources for info and buying festoons.

If any are close to you they all have festool trained folks there who can help you even if you didn't purchase it from them. They are pretty good people.

I went to both Anderson Plywood and Woodcraft in Fountain Valley (OC) to ask about the 5mm bit breakage and rough cutting last week, but hadn't seen the switch move on its own when I was there. They BOTH suggested that I either wasn't holding the Domino firmly or that I was leveraging the Domino up slightly when I was pushing to cut. I didn't think so, but was especially careful the time. Both had heard people complain about 5mm bit breakage and thought this was the culprit. I think I've got something else going on here.

I have probably another 60 or so dominos to cut later today, so I'll see how it goes. I was using the 10mm bit when I saw the switch move. These will be with an 8mm bit. Thanks for all the input! I'll report back later today's when I'm done.

Sadly, I don't think it's still under warranty. I believe I purchased it from my local Rockler back when they were selling Festool, so it's been a while.

 

[grbmds]

It's hard to believe that accidentally changing mortise size with the machine off would do that type of damage. I've done it myself on several occasions before I got used to using the Domino. No negative result.

I think it is a service issue and suggest calling Service or filling out the online ticket. That is the way to resolve the problem.

 

[copcarcollector]

It's hard to believe that accidentally changing mortise size with the machine off would do that type of damage.

I have seen the cut away Domino model, and the size of these gears, I think its just a recommended practice to change the size with the machine on. Yes it can be done with the power off, but it may result in damaging the gears. Yes I have seen the trainer do it with the power off, more as a warning of what not to do, but he can fix it if it breaks!

Maybe Festool or an informed dealer, like Shane or Rick, can chime in here--

I am pretty sure the 700 is the opposite.

 

[LDBecker]

Ended up re-cutting the part of the handrail that I had finished- I APPARENTLY don't remember enough of my 8th grade geometry class to make an adequately curved handrail out of straight stock - got it this time, though (15 degree angles, not 22.5-was too big an arc). ANYWAY, I recut and re-Dominoed the red oak rail stock and the width dial has settled down, but on the narrowest setting, the tenons are fairly loose (10mm tenons). I'm sure this is connected to the self-moving width dial AND the breaking bits. The Domino cuts are usable, but it isn't quite right. I'm going to finish the project and get it in for (sadly, over 3 yrs and out of warranty) service. Ick.
I need to finish this project because my wife's knee replacement surgery was moved up to TODAY and she won't safely make it up the porch steps without them. (She's in recovery now, all went well in the surgery). Thanks for all he suggestions and input.

 

[ear3]

How loose is loose?  Do they fall out when you turn the piece upside down (such that gravity is working on the dominoes)?  I also get a range of snugness/looseness in my dominoes depending on the type of material being cut and what part of the grain (face vs. end grain), but the disparity is never to the point where the dominoes slide out on their own.

Ended up re-cutting the part of the handrail that I had finished- I APPARENTLY don't remember enough of my 8th grade geometry class to make an adequately curved handrail out of straight stock - got it this time, though (15 degree angles, not 22.5-was too big an arc). ANYWAY, I recut and re-Dominoed the red oak rail stock and the width dial has settled down, but on the narrowest setting, the tenons are fairly loose (10mm tenons). I'm sure this is connected to the self-moving width dial AND the breaking bits. The Domino cuts are usable, but it isn't quite right. I'm going to finish the project and get it in for (sadly, over 3 yrs and out of warranty) service. Ick.
I need to finish this project because my wife's knee replacement surgery was moved up to TODAY and she won't safely make it up the porch steps without them. (She's in recovery now, all went well in the surgery). Thanks for all he suggestions and input.

 

[LDBecker]

How loose? I am accustomed to them being tight enough that they can be difficult to pull out when dry-fitting them. These now are pretty much to the point of falling out. I think loose enough that the joint is weakened.

I will take it to my local Woodcraft and compare it to one of theirs- the owner offered to check it out for me...

 

[Rick Christopherson]

I don't think I changed the width setting with the machine not running, but I may have. I went back over the supplemental manual before I started this project and noted that concern.  I bet most people have, in fact, changed that switch with it off. Is that really a death sentence for the Domino 500. If so, it's far too easy to do, and not marked on the machine to avoid doing it...

Any other ideas? Anyone else possibly turned that switch with the machine off?

As has been noted by some of the Festool trainers, you can rotate the dial when the machine is off as long as you don't force it. The only reason why I don't say that in the manual is because it is easier to explain than to provide various conditions and cause confusion.

I don't know what would have caused yours to loosen up like this, however.

 

[LDBecker]

I was at Anderson Plywood in Culver City, CA, yesterday, and their normal Festool sales guy was there AND the local Festool rep. I told them my tale of woe (vibrating width dial, rough cuts, dial changing on its own, broken 5mm bits) and they both basically confirmed that a) I'm a dufus (in a nice way, of course), and b) that all my Domino problems are likely related to changing the dial with the motor not running. I'll bring it into them to ship off when I'm done with this project - it SEEMS ok on the 8 and 10mm bits, and has settled down - cutting ok (a little looser mortises than it should, but probably ok). Thanks so much for all the advice!

 

[grbmds]

Sincerely doubt that's the cause. I've done it at least twice without thinking. I also did it in a Festool class one day by mistake. No harm done. I would have just sent it in and let them sort it out to begin with. The tool has a warranty and if, by chance, it was caused by changing widths when the machine was off and they won't cover it, you'd have probably sent it in anyway. The Domino is too expensive to replace instead of repair. Service is always the final word on these things and my experience is that, unless it looks as if there was abuse of some sort by the owner, they are likely to cover it anyway. They're just that way.