Domino Mortise is too narrow

[tjskinny]

I just downloaded the Domino ebook
https://www.festoolusa.com/knowledge/downloads#Magalogs

And this is what it stated under Domino mortise width selection:

DF 500
1 The standard width, corresponding exactly to the domino width: 13 mm plus the cutter diameter
2 The average mortise width, giving the domino some clear- ance (6 mm): 19 mm plus the cutter diameter
3 The largest mortise width, providing a lot of clearance (10 mm): 23 mm plus the cutter diameter

DF 700
1 The standard width for precise routing is: 13.5 mm plus the cutter diameter
2 The mortise width with clearance (3 mm) corresponds to: 16.5 mm plus the cutter diameter

As with some of the others experience, all the domino slots that I have cut in solid wood and plywood with my DF500 are a tight fit in their respective holes. I can't push them in or pull them out of their holes without the use of pliers.

 

[bkharman]

Luke,

Any chance you are over tightening the bit?  I usually just hand tighten, and it will firm up as it spins. The other thing is that you might have a manufacturing defect. If there are too many threads on the shaft or the shaft is just slightly short, it would cause a slightly less-wide domi-hole.

Let us know what they come back with. Next time I am in Orange or LA, I will let you know. I will be in Mountain View next week for a few days, but that is a little hike!

Where is Elon on that tube of his?!?!?

Cheers. Bryan.

Sent from my iPhone using Tapatalk

 

[grbmds]

I certainly agree the Dominos themselves are a tight fit. However, I can almost always push them into the slot halfway without using a mallet and, if not, then a couple of passes over rough sandpaper does. I've never even thought of using a block plane. Summers in Illinois are almost always humid and I don't seem to have more trouble during summer than winter (although I do keep the humidity in my basement shop between 50% - 60% in summer.

I assume that, over the life of your Domino, you have purchased more than one batch of Dominos. If not, is it possible that the bag of Dominos you got was not up to spec (or that the tolerance of Festool specs is not so precise as to allow some batches to be just enough to large they don't seem to fit)?

 

[waterloomarc]

I too always have to shave my dominos down in order to get them to fit. It's annoying but frankly I just thought it was the nature of the beast. I have to do it for all sizes as well. I will go measure my dominos and slots on Monday and see what I've got.

 

[Cheese]

And this is what it stated under Domino mortise width selection in their ebook:

DF 500
1 The standard width, corresponding exactly to the domino width: 13 mm plus the cutter diameter

DF 700
1 The standard width for precise routing is: 13.5 mm plus the cutter diameter

It's interesting to note that the 700 was designed from the git-go to cut a wider mortise than the 500. So it could also be interesting to cut #8 & #10 mortises with both a 500 and a 700 and compare the fit with the same Domino.

 

[iamnothim]

Thanks to everyone for relating your experiences, and providing ideas.
The difference between the mortise width and a 5mm Domino width is 1.55mm
Doesn't sound like a lot but it is.  Even on soft wood they won't go in without pliers or a mallet and the Mortise will be damaged.  The the tenon must be shaved. On oak, cherry, or plywood. It just can't be done with a mallet or pliers.  You'd  smash your finger with the mallet. A  total mess. 1mm or so must be removed and sandpaper would take a long time.  Believe me if I didn't have to pull a Domino down the sole of a block plane with my thumb and index finger I wouldn't.  Two years without blood but it's just a matter of time.

 

[Birdhunter]

Please let us know what the repair people find when you get the unit back.

 

[Kwomer2000]

Definately keep us posted, I hope you get this traightened out!

 

[HarveyWildes]

Thanks to everyone for relating your experiences, and providing ideas.
The difference between the mortise width and a 5mm Domino width is 1.55mm
Doesn't sound like a lot but it is.  Even on soft wood they won't go in without pliers or a mallet and the Mortise will be damaged.  The the tenon must be shaved. On oak, cherry, or plywood. It just can't be done with a mallet or pliers.  You'd  smash your finger with the mallet. A  total mess. 1mm or so must be removed and sandpaper would take a long time.  Believe me if I didn't have to pull a Domino down the sole of a block plane with my thumb and index finger I wouldn't.  Two years without blood but it's just a matter of time.

A simple jig would reduce the chance of flaying your finger.  I've made a couple for trimming them to length.

 

[ear3]

But that would take all the dangerous fun out of it.

Thanks to everyone for relating your experiences, and providing ideas.
The difference between the mortise width and a 5mm Domino width is 1.55mm
Doesn't sound like a lot but it is.  Even on soft wood they won't go in without pliers or a mallet and the Mortise will be damaged.  The the tenon must be shaved. On oak, cherry, or plywood. It just can't be done with a mallet or pliers.  You'd  smash your finger with the mallet. A  total mess. 1mm or so must be removed and sandpaper would take a long time.  Believe me if I didn't have to pull a Domino down the sole of a block plane with my thumb and index finger I wouldn't.  Two years without blood but it's just a matter of time.

A simple jig would reduce the chance of flaying your finger.  I've made a couple for trimming them to length.

 

[iamnothim]

Still no box from UPS. .... I'll keep y'all posted. 
I am far too impatient to build jigs (except for a shooting board).  I think about making them then I figure out how to spend 4x time on the task without one.  It's weird I lack the vision.
I really should make some Fine Woodworking jigs.

 

[ear3]

Speaking of which, I have coming in the mail this book that was recommended to me: Robert Wearing, "Making Woodwork Aids & Devices"
https://www.amazon.com/gp/product/1861081294/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Still no box from UPS. .... I'll keep y'all posted. 
I am far too impatient to build jigs (except for a shooting board).  I think about making them then I figure out how to spend 4x time on the task without one.  It's weird I lack the vision.
I really should make some Fine Woodworking jigs.

 

[iamnothim]

Speaking of which, I have coming in the mail this book that was recommended to me: Robert Wearing, "Making Woodwork Aids & Devices"
https://www.amazon.com/gp/product/1861081294/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Way Cool!  thanks

Still no box from UPS. .... I'll keep y'all posted. 
I am far too impatient to build jigs (except for a shooting board).  I think about making them then I figure out how to spend 4x time on the task without one.  It's weird I lack the vision.
I really should make some Fine Woodworking jigs.

 

[iamnothim]

Update
No Box

 

[iamnothim]

News Flash
I called Festool Repair.
Brett said they are waiting on a part to arrive from Germany and they should have it the first part of next week.

I kept my composure during the call.

 

[Birdhunter]

Thanks for the update.

 

[iamnothim]

My Domino is either on it's way or still being repaired

I called for status.  After a few minutes on hold it went to voicemail. Do I know nothing.

I went to the repair ticket email and clicked the link to check the repair status.  The link was broken.  I got a 404 page.  This is so unprofessional.  I need the tool.  it's been over 6 weeks

 

[copcarcollector]

It seems that certain business aspects are falling apart out there in Indiana....  [sad]
[member=57769]TylerC[/member] , I think Tyler is on vacation but maybe he can get someone to check for you...

I would consider just buying a new machine, use the crap out of it for 29 days, then return it. Maybe in that timeframe your original machine will be back from HQ

 

[rljatl]

Maybe I am giving him too much credit, but it seems that things have not been the same at the USA Festool HQ since Shane left.  He was always on top of things here on the forum and worked well with the team at the USA repair facility.  I just do not remember these kind of issues when he still worked for Festool, even though he lives hundreds of miles away in a different state.

 

[iamnothim]

It seems that certain business aspects are falling apart out there in Indiana....  [sad]
[member=57769]TylerC[/member] , I think Tyler is on vacation but maybe he can get someone to check for you...

I would consider just buying a new machine, use the crap out of it for 29 days, then return it. Maybe in that timeframe your original machine will be back from HQ

Great idea
Should have done that a month ago