Generic Accessory Block for FS Guide Rail

[duburban]

I'm with green on one block perhaps wider. I'll also be happy with whatever.

The only question I would toss out there is, would it make much of a difference, in use and functionality, to others if the blocks were a hair wider?

I ask because if one were to cut them in half, as you suggested earlier, then taking into account the kerf of a standard blade would allow the shorter, final pieces to come out at your original suggested width of 60mm...

This then directs one to ask if 120mm is good, would something wider be better, which would allow the end user even more flexibility.

Does anyone have a problem if I got with one large block that you can use as is or cut in half to get a pair of small blocks?

RMW

 

[UncleJoe]

I would be interested in a couple

 

[rmwarren]

The blocks I made (pictured below) are 60mm long (parallel to the rail) and only 50mm wide - they protrude from the rail about 30mm. They work okay for the Incra track but if I made another set I would make them 60mm wide to give a little more depth for attaching the rails.

At 60mm long they are reasonably stable and don't flex much on the rail. Longer is better in this case, within reason. Setting aside cost for a moment (Acetal is costlier than aircraft grade aluminum) I would probably make them 75 - 80mm to give them more area in contact with the rail.

I can see what they would cost at say 155mm, allowing for a 5mm kerf and (2) 75mm blocks.

Does that sound like a good compromise?

RMW

I'm with green on one block perhaps wider. I'll also be happy with whatever.

The only question I would toss out there is, would it make much of a difference, in use and functionality, to others if the blocks were a hair wider?

I ask because if one were to cut them in half, as you suggested earlier, then taking into account the kerf of a standard blade would allow the shorter, final pieces to come out at your original suggested width of 60mm...

This then directs one to ask if 120mm is good, would something wider be better, which would allow the end user even more flexibility.

Does anyone have a problem if I got with one large block that you can use as is or cut in half to get a pair of small blocks?

RMW

 

[rmwarren]

Another option is a block that attaches to the rail and has tapped holes for mounting whatever you want to it. This was an older design I played with that is 100mm long and had 2 thru holes that I think were 8mm and 2 more tapped holes in 6mm.

[attachthumb=#]

The block is taller to give the holes clearance above the other t-track on the rail so you can attach something to it that faces to the guide side of the rail.

I seem to recall this was less costly than the current design but I have to look back. Is this approach preferable to the design below?

RMW

 

[Michael Kellough]

I'd prefer this even if it does lock me into using the Incra track because there isn't anything nearly as good as the Incra T-track Plus for the purpose, and the cost of T-track Plus is only slightly higher than generic t-track. The scales are also available in metric, just wish they had a metric/Imp. combo scale.

My next preference would be a two part bracket that makes it easier to un-mount the T-track from the guide rail. One part would be similar to the simpler older design that you just posted but the holes would be vertical rather than horizontal. The second part would could be just a simple slab that bolts on top of both the T-track and the rail bracket. Ideally the installed height of the rail bracket would be equal to the height of the T-track Plus. (Didi i mention that I plan to use T-track Plus?  )

 

[bruegf]

I'd be interested in a pair

Fred

 

[tbellemare]

What material are you planning to use?

Does everyone plan to use the end result at the same ambient temperature?

Have you contemplated the Coefficient of Thermal Expansion of the material vs the same of the Guide Rail?

There are several reasons why the Festool products have adjustable Guide Rail attachment mechanisms.

Tom

 

[rmwarren]

Tom - nothing nearly that scientific.  [huh]

I would expect to use Acetal, but could as easily use aluminum. The set I made myself from Acetal has been inside and outside along with the rail, at room temp and around freezing. I have not noticed any change in fit.

Your raise a good point. I think the bigger issue regarding having some adjustment could crop up with small differences of size between individual rails. I have 3 rails and all the t-slots measure just +/- 16.1mm outside and +/- 8.25mm inside, they are consistent within the limits of accuracy of my cheap digital calipers.

RMW

What material are you planning to use?

Does everyone plan to use the end result at the same ambient temperature?

Have you contemplated the Coefficient of Thermal Expansion of the material vs the same of the Guide Rail?

There are several reasons why the Festool products have adjustable Guide Rail attachment mechanisms.

Tom

 

[PaulMarcel]

I'm interested in a pair; if it comes as a long block I cut in half, that's fine.  I'd prefer the wider suggestion because I can always cut it narrow if necessary, but hard to glue something on to make it wider.

Nice idea; looking forward to it!

 

[kevros]

1 pair for me
Thanks
Kev

 

[Robert]

One Pair for me. Thanks

 

[John Stevens]

I can see what they would cost at say 155mm, allowing for a 5mm kerf and (2) 75mm blocks.

Does that sound like a good compromise?

155 x 60 would be perfect for me.  One of these (155x60), or one pair if you go with 60x60 or 75x60.

Regards,

John

 

[rmwarren]

I will finalize the design for the 155 by 60 version and get them made up, should take about 4 weeks. I can make up a jig to cut them in 1/2 for anyone who wants them that way.

Thanks,

RMW

 

[GreenGA]

Hey, why bring samples of everything you're working on to Somerset at the end of the month?  [poke]

I will finalize the design for the 155 by 60 version and get them made up, should take about 4 weeks. I can make up a jig to cut them in 1/2 for anyone who wants them that way.

Thanks,

RMW

 

[rmwarren]

Good idea, I will.

Did we settle on Saturday to meet p for breakfast beforehand?

RMW

Hey, why bring samples of everything you're working on to Somerset at the end of the month?  [poke]

I will finalize the design for the 155 by 60 version and get them made up, should take about 4 weeks. I can make up a jig to cut them in 1/2 for anyone who wants them that way.

Thanks,

RMW

 

[GreenGA]

Not yet.  I was going to wait until the Monday before the show to put out feelers here on the FOG to determine who, if any, were interested in meeting before the show, which day and start soliciting suggestions of when and where to meet for breakfast.

I am anal about food but have no idea of where to eat in the area.  My son lives off Exit 5 of 287 (the exit before the WW Show exit, 9...) but he is not much help since he and his wife rarely have breakfast outside the home.

The only place I know, but cannot vouch for, is off 287, Exit 5, turn left, down the road about 1/4 mile on the right. Luckily, Starbucks is around the corner from this restaurant so I will be all set to hit the show.  [thumbs up]

Good idea, I will.

Did we settle on Saturday to meet p for breakfast beforehand?

RMW

 

[waho6o9]

Maybe make a router attachment on top as well.

I'm down for a pair.  [big grin]

 

[ByrdieMan]

Count me in!

 

[rmwarren]

Latest prototype. This is 75mm long but only 40mm wide, about 12mm thick. 40mm is too narrow (20mm projection), I am going back to 60mm. I made these for another idea that did not pan out. I think I am also back to making singles rather than doubles that have to be cut in 1/2, it turned out that there was no cost savings in the double.

[attachthumb=#]

The groove depth is sized to leave 1/4" underneath the protrusion when attached to a guide rail, this seems like the most useful generic configuration to be able to mount other stuff underneath it.

My question for everyone is how many prefer to have them made with the pocket for an Incra track versus routing it yourself? The cost increase of the extra machining is minimal, if most folks plan to use them for that purpose then it makes sense to go that way rather than making them more generic.

Please let me know your preference. The last pieces of the Rip Dogs are supposed to arrive Tuesday, after I get them shipped out I will focus on completing these gizmos.

Thanks,

RMW

 

[Lucky Dave]

One vote for Incra.