Homemade guide rail connectors (not your typical ones)

[overanalyze]

As far as I remember Makita Supplying this type of connector with their track saw. I personally found it fiddly keeping to parts together.

That's why I attached the two pieces to each other with a small screw.

 

[JZ Bowmannz]

Made my version tonight following you guy's lead.

Modified to what I think a little better config:

both pieces are 18" long instead of 12";
they are true 12 mm wide stocks - so no more material removal;
one piece is 4.0 mm thick, which will receive all tapping operation to have a better thread engagement;
other piece is 2.0 mm thick, which only has (2) countersink through holes to keep two pieces together;

I did try them, connected much more solidly than my old Festool ones.

Thanks SVAR!

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[duburban]

sweet. i'm totally doing this asap. where did you find the stock?

 

[JZ Bowmannz]

Duburban,

Stocks came from Alro Steel here locally in Ann Arbor, Michigan area. We are in automotive world, and it's easier to get stuff in metric locally than the rest of the country I think.

http://www.alro.com/

 

[duburban]

Thanks. This type of material is not something I've spent much time shopping for.

 

[rustym]

McMaster-Carr has 2mm x 12 and 4mm x 12 for like $10 for 2 3ft pieces. Just ordered some.

Rusty

 

[rustym]

Just received the steel from McMaster-Carr and it is a perfect fit.  Won't have to do any sizing just a file swipe on the sharp edges.  Now to drill for the set screws and I'll be ready.

 

[promark747]

Rusty,

What was the part number from McMaster-Carr?

Let us know how it goes drilling the set screws.

 

[rustym]

Low carbon steel 4mm x 12mm x 3'  6775T43  $5.84
Low Carbon steel 2mm x 12mm x 3'  6775T23 $4.69

With shipping it was less than $20

I'll post a couple pics after I get them drilled and together. One piece of each cut in half will yield a set of connectors.

A special thanks to Mr. Bowmannz for the sizes of the steel.  It wasn't hard to find the right size at McMaster-Carr.

 

[JZ Bowmannz]

Rusty,

I used only #8 for connecting two piece together, and #10 x 1/4" set screws.

Figure if use M6 set screws, more than half width of the material would be drilled out on the 4 mm piece, not sure that will effect the total strength of the connectors. And 1/4" long set screws will stay below the suface of the rail in the slots.

Hope that helps.

 

[promark747]

JZ/Rusty,

Thanks...that was the last part I was wondering about -- which size set screws to use, and whether to use the conical type.

 

[JZ Bowmannz]

The hex hole for the Allen Wrench in #10 set screws was too small,and I was afraid to strip it when I crank it, so I found these with slot at local hardware store, they have slots just like the Festool ones.

 

[rustym]

Just finished one connector.  Still have to add the little screws to hold the bottom piece to the top piece and finish the second connector.  But I must say the connector locks up in the rail quite nicely.  Looks like it is going to work perfectly.
BTW, I used 10x32 1/4 setscrews and they work great.
I hope to cut some ply this weekend so I'll be putting two 55" rails together so we'll see how they really work.

 

[greymann]

I really like this design over the standard connectors.  Hope Festool will finally take notice.

If you are looking for a place to store these while not connecting two rails together, here's a suggestion.

I use the 1900 rail a lot on my homemade tables and find that it has more flex than I would like, especially when resting the saw on a portion hanging over the end of the table.  I have taken to using the standard connectors in the underside slot as stiffeners and have been pleased with the results.  I believe your longer bars will be even more effective.  I usually put one near the close end of the rail and the other nearer the center.

I also never have to remember where I put them.

Dick Perry

 

[Slartibartfass]

Here are mine. Roughly 15" long.

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[weekendwarrior]

[member=32690]Slartibartfass[/member]- that's a nice looking drill press/milling vice.  What model is it?

 

[Slartibartfass]

[member=32690]Slartibartfass[/member]- that's a nice looking drill press/milling vice.  What model is it?

[member=28856]weekendwarrior[/member] its actually a Sherline Mill. See http://www.sherline.com

 

[weekendwarrior]

Would these homemade connectors also work as MFT connectors?

 

[sgt_rjp]

Speaking of MFT connectors, are there any threads concerning them(yours or others)?  I just ordered a second MFT/3 and was already thinking about doing something with 8020 when I saw yours.

 

[JZ Bowmannz]

Would these homemade connectors also work as MFT connectors?

The MFT connectors are 14mm x 9mm.

You would need some different stocks for that purpose.

I would try layer of 12mm x 9mm stock plus a layer of 2mm x 9mm stock.

There are something called "Key Stock" available that are 14mm x 9mm. You have to do some machining of course.

http://www.mcmaster.com/#key-stock/=wk9rww