Guide rail connector issues---

[PeterK]

Ok - maybe it is just me having this issue as a search didn't turn up much.

My guide rail connectors drive me crazy. The set screws seem to oxidize over time and become really difficult to tighten. When I put the rails together, now it seems the screws are tightened but quite often they aren't - just tight in the bar so the rails shift during use. Might be that they are using a dis-similar metal for the screws? Anyhow, is there a better connector to use? Mine are the older series rails that use 2 connectors. Every screw in them (8) have become difficult to move and the screw driver slot is getting wallowed out from the force required to turn them.

Sure wish there was a longer higher quality connector bar available. I don't have room in my shop to store the long rails so am forced to connect them. Looked at the Betterley rail alignment tool but see that just helps align and must be removed to actually run a tool down the rail so that is no help. There just has to be a better way to join rails!!!! Any bright ideas?

Pete

 

[Theshipstore]

Pete  I had a similar problem with my connectors. I removed the screws sprayed some Boeshield on the threads and ran them back in and out a few times. No longer a problem for me.

As far as Connecting them together I bought the Betterly Straight Line Connect and my issues on that went away also.
Yes it is somewhat pricey at 99.00 but it works so well I was really amazed at the ease and accuracy of putting my rails together now.
Right now the only rails I put together in the shop are my LR-32 rails, on site I use to 55" rails for longer cuts.

Hope this helps some

Sal

 

[PeterK]

As a follow-up.
I tried to remove the connector bars from the rail that I leave them attached to and the screw heads just twisted off. Will have to drill them out to get them out now. Sheesh!

 

[RONWEN]

Ok - maybe it is just me having this issue as a search didn't turn up much.

My guide rail connectors drive me crazy. The set screws seem to oxidize over time and become really difficult to tighten. When I put the rails together, now it seems the screws are tightened but quite often they aren't - just tight in the bar so the rails shift during use. Might be that they are using a dis-similar metal for the screws? Anyhow, is there a better connector to use? Mine are the older series rails that use 2 connectors. Every screw in them (8) have become difficult to move and the screw driver slot is getting wallowed out from the force required to turn them.

Sure wish there was a longer higher quality connector bar available. I don't have room in my shop to store the long rails so am forced to connect them. Looked at the Betterley rail alignment tool but see that just helps align and must be removed to actually run a tool down the rail so that is no help. There just has to be a better way to join rails!!!! Any bright ideas?

Pete

We picked up on another forum member's idea and are going to release a product that is longer than the Festool connectors and is made of a very rigid tool steel.  It's based on two pieces of steel so the set screws aren't pushing & marring the aluminum guide rails.
[attachimg=#]

 

[PeterK]

Hope it gets released soon!!!!
I will be ordering those.  [big grin]

 

[Svar]

Peter,
1) You can make connectors yourself like so http://festoolownersgroup.com/festool-jigs-tool-enhancements/homemade-guide-rail-connectors-(not-your-typical-ones)/
2) You can get new Allen set screws for your existing connectors at any hardware store. I believe they are M6 (metric).
3) I don't know the dimensions of Festool connectors, but perhaps there is enough space there to slip a thin strip of metal underneath (as in option 1) to act as a cushion between the screws and bottom of the T-slot.
4) It appears that Makita makes something similar to option 1. I’ve never seen them myself, but on the low resolution pictures on the web they seem to consist of two parts. It must be the right size because Makita saw is compatible with Festool rail.
5) If option 3 does not work you could grind a notch in the bottom of the connector and place a spacer/washer to prevent the screw from digging into aluminum like so:

[attachimg=#]

P.S. Mafell makes the most advanced connectors: http://www.dm-tools.co.uk/browse.php/section/7327/level/4
They self allign rail similarly to Betterley rail alignment tool.

 

[cliffp]

Svar, regarding your option 3, I was wondering whether it might be possible to glue strips of feeler gauge to the connector under where the screws exit? I tried a 0.25 mm 'blade' and this seemed to be thin enough to allow the connector to slide in alright and also thick enough to withstand the stress of the screw twisting and pushing against it (my gut feeling rather than anything scientific).

 

[Svar]

I think 0.25 mm steel might work. Better than nothing. You could flatten the end of the screw to distribute pressure to larger area. Since there will be a spacer it will reduce the chance of screw "wandering" as you tighten it.

 

[richard.selwyn]

Ok - maybe it is just me having this issue as a search didn't turn up much.

My guide rail connectors drive me crazy. The set screws seem to oxidize over time and become really difficult to tighten. When I put the rails together, now it seems the screws are tightened but quite often they aren't - just tight in the bar so the rails shift during use. Might be that they are using a dis-similar metal for the screws? Anyhow, is there a better connector to use? Mine are the older series rails that use 2 connectors. Every screw in them (8) have become difficult to move and the screw driver slot is getting wallowed out from the force required to turn them.

Sure wish there was a longer higher quality connector bar available. I don't have room in my shop to store the long rails so am forced to connect them. Looked at the Betterley rail alignment tool but see that just helps align and must be removed to actually run a tool down the rail so that is no help. There just has to be a better way to join rails!!!! Any bright ideas?

Pete

We picked up on another forum member's idea and are going to release a product that is longer than the Festool connectors and is made of a very rigid tool steel.  It's based on two pieces of steel so the set screws aren't pushing & marring the aluminum guide rails.
[attachimg=#]

Put me down for two sets pleas ASAP

 

[Paul G]

Ok - maybe it is just me having this issue as a search didn't turn up much.

My guide rail connectors drive me crazy. The set screws seem to oxidize over time and become really difficult to tighten. When I put the rails together, now it seems the screws are tightened but quite often they aren't - just tight in the bar so the rails shift during use. Might be that they are using a dis-similar metal for the screws? Anyhow, is there a better connector to use? Mine are the older series rails that use 2 connectors. Every screw in them (8) have become difficult to move and the screw driver slot is getting wallowed out from the force required to turn them.

Sure wish there was a longer higher quality connector bar available. I don't have room in my shop to store the long rails so am forced to connect them. Looked at the Betterley rail alignment tool but see that just helps align and must be removed to actually run a tool down the rail so that is no help. There just has to be a better way to join rails!!!! Any bright ideas?

Pete

We picked up on another forum member's idea and are going to release a product that is longer than the Festool connectors and is made of a very rigid tool steel.  It's based on two pieces of steel so the set screws aren't pushing & marring the aluminum guide rails.
[attachimg=#]

Are these shipping? Huge improvement!!

 

[sancho57]

Ok - maybe it is just me having this issue as a search didn't turn up much.

My guide rail connectors drive me crazy. The set screws seem to oxidize over time and become really difficult to tighten. When I put the rails together, now it seems the screws are tightened but quite often they aren't - just tight in the bar so the rails shift during use. Might be that they are using a dis-similar metal for the screws? Anyhow, is there a better connector to use? Mine are the older series rails that use 2 connectors. Every screw in them (8) have become difficult to move and the screw driver slot is getting wallowed out from the force required to turn them.

Sure wish there was a longer higher quality connector bar available. I don't have room in my shop to store the long rails so am forced to connect them. Looked at the Betterley rail alignment tool but see that just helps align and must be removed to actually run a tool down the rail so that is no help. There just has to be a better way to join rails!!!! Any bright ideas?

Pete

We picked up on another forum member's idea and are going to release a product that is longer than the Festool connectors and is made of a very rigid tool steel.  It's based on two pieces of steel so the set screws aren't pushing & marring the aluminum guide rails.
[attachimg=#]

I dont have a issue with my connectors for my guide rails.

But if you were to make longer connectors for the MFT Id definitely be interested in a set of those.

 

[RONWEN]

Ok - maybe it is just me having this issue as a search didn't turn up much.

My guide rail connectors drive me crazy. The set screws seem to oxidize over time and become really difficult to tighten. When I put the rails together, now it seems the screws are tightened but quite often they aren't - just tight in the bar so the rails shift during use. Might be that they are using a dis-similar metal for the screws? Anyhow, is there a better connector to use? Mine are the older series rails that use 2 connectors. Every screw in them (8) have become difficult to move and the screw driver slot is getting wallowed out from the force required to turn them.

Sure wish there was a longer higher quality connector bar available. I don't have room in my shop to store the long rails so am forced to connect them. Looked at the Betterley rail alignment tool but see that just helps align and must be removed to actually run a tool down the rail so that is no help. There just has to be a better way to join rails!!!! Any bright ideas?

Pete

We picked up on another forum member's idea and are going to release a product that is longer than the Festool connectors and is made of a very rigid tool steel.  It's based on two pieces of steel so the set screws aren't pushing & marring the aluminum guide rails.
[attachimg=#]

Are these shipping? Huge improvement!!

We still are developing the final design -- probably not available until late summer.

 

[Corwin]

I gather that interested parties will have to visit your website to learn of the release of this new product since it will be in direct competition with the rail connectors that Festool sells.  Understandable position for Festool, but kind of a shame too.  In any event, congratulations on all your products!  [thumbs up]

 

[Paul G]

Are these shipping? Huge improvement!!

We still are developing the final design -- probably not available until late summer.

If you need another beta tester I'm your man  [thumbs up]

 

[RONWEN]

I gather that interested parties will have to visit your website to learn of the release of this new product since it will be in direct competition with the rail connectors that Festool sells.  Understandable position for Festool, but kind of a shame too.  In any event, congratulations on all your products!   [thumbs up]

Hey Corwin, We very much respect & honor the forum rules.  I think Ryan sends out notices of new products to his customer list. 

 

[Festoolian]

We picked up on another forum member's idea and are going to release a product that is longer than the Festool connectors and is made of a very rigid tool steel.  It's based on two pieces of steel so the set screws aren't pushing & marring the aluminum guide rails.

All steels have the same stiffness (rigidity).  Two piece guide rails may not need tool steel.  Maybe save us some $$$.

 

[ali]

Has anyone ever tried the Makita connectors on their guide rails?

 

[tonylumps]

Has anyone ever tried the Makita connectors on their guide rails?

Yes and it works great A little learning curve the first time. It consist 2 bars per set The thinner of the 2 has a hole at each end .Just align one of the end set screws in this hole screw in just enough to catch (it will not go thru)and slide it into the track. Tighten .You will not believe how tight it holds. Now again you will need 2 sets

 

[rst]

Makita P-45777 Guide Rail Connector Kit -  I just ordered two from Amazon.  I will update after receipt.

 

[jimmylittle]

sign me up for a set of those!

I have replaced screws in mine SO MANY times, I just keep a box of spare screws in the Sys that holds my MFT bits and bobs.  They just disappear.  I can't keep a long rail, my van isn't big enough.  I had a 108" for just a few weeks before I managed to bend it by moving it in a vehicle that is too small.

I cut that sucker down to a 55", so it wasn't a total waste.  Now, I have a hard case I built that holds all my rails (55" max) and a 4' level, plus the aluminum fence for the MFT.  All the straight metal stuff goes in there and stays straight.

Because of this, I'm constantly mating rails and would love a better solution, either from Festool or _someone else_.