Kapex base is not level

E

eiden

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Joined
Dec 27, 2009
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After several months of thinking, I took the final step and bought a Kapex. I looked forward to getting this saw for several weeks. Last Friday (yesterday) it was delivered, and I enjoyed myself for several hours while I set it up and did some test cuts :) After a while, started to notice that some cuts were very out of angle ...

After several hours of reading the manual (the official and supplement manual) and doing some "trial and error", I remembered a thread where a guy had a similar problem with the base of his Kapex. So I took out the longest straighedge I have (the MFT/3 fence), and laid it on the bed on the saw. And guess if I was disappointed!

If the saw is set with a miter angle of 0 degrees, and I press the straighedge down against the saw on the right side, there is a gap of 2mm (0.07 inches) on the left side. If I set a miter angle of 60 degress, the gap increases to around 4mm (0.15 inches). It's so much that I can actually fit two creditcards under the straightedge!

It seems that the middle part of the saw (the one that pivots) is out of alignment.

I have uploaded a video to youtube of me placing the straightedge (sorry about the crappy quality, it's recorded with a cellphone):
30012010009.mp4

Is there anybody here who have had similar probles with their Kapex?
 
This is the only thing I could suggest besides calling Festool and talking to them on Monday.

It seems the saw table moves back and forth really easy.  I wonder if the bolt under the kerf plate is a little loose.

Other than that, call them monday, I know for certain they will help you out one way or the other.
 
It's a little hard to see where your rocking your straight edge against, but it looks like your tipping it down on the right side against the crown stop extensions.  It's hard to see what the high point is because your arm is in the way.  The crown stop extensions are by design just a slight bit lower then the base  of the saw.  Try eliminating the crown extensions and remove the plastic kerf plate and then recheck.  the turntable should be dead flat.
 
@WarnerConstCo:
I'll think you might be onto something. If I press the kerf plate down really hard, the gap becomes smaller. I will try to tighten the bolt tomorrow. I don't have the proper tools at hand right now.

@wnagle:
It's probably a bit hard to see on the video, but the right crown extension is not attacted to the saw. Only the left one is attached. (at 00:33 in the video, I move my arm back)
 
The plastic kerf plates have been known to somtimes warp a bit and make a high spot as Warner mentioned.  Best bet is to make one of your own out of wood and make it zero clearance.  There are dimensions for the kerf plate in Rick's kapex manual here...

http://www.waterfront-woods.com/festool/index.htm

Edit:  Also, is the saw clamped to a table?  This could cause racking too, so I'd remove any clamps too when checking.  If it still seems off after all of the above, I'd call Festool support.  They are the best!
 
But for a $1300 saw the end user shouldn't have to replace parts or make a bunch of trial and error adjustments.  This is disappointing.
 
@wnagle:
I've tried with and without clamping it to the table.

As WarnerConstCo mentioned, the bolt under the kerf plate might be a bit loose. I will try to tighten it and see if that solves the problem.

@JohnDistai:
I totally agree with you. I'm really dissapointed considering that this saw is very expensive. I paid 1360 GBP for it, witch is equivalent to over $2100..

If a base that is not level got through QA at the factory, I'm just wondering what else might be wrong with the saw :(
 
If the throat plate is the problem I wouldn't get your feathers ruffled just yet.  Festool will replace it or better yet make the wooden zero clearance plate... it is much better in the long run.  However if that's not the problem, Festool will make it right or you can get a refund within 30 days since you just got it.  It's hard to lose.  

I have the Kapex... made my own zero clearance throat plate which is a consumable and will need redone at some point, kinda like replacing a worn blade.  

After making the throat plate, I set it up, adjusted the lasers, and it has been perfect since.  I really like it, glad I bought it, wouldn't trade it for any other saw on the market.
 
FWIW, I've had my Kapex for a little over a year now and I've got the same issue.  I've used a zero clearance plate for a while so I know that's not the issue.  Just like the OP when I swing the saw 45 degrees in either direction I end up with a 1.5mm gap on the opposite end of the saw base.  Any ideas?
 
wnagle said:
I don't understand where your gap is.  Can you post a pic?
Click to expand...
You can see it in the video.When he puts a straight edge on the miter table,there is a gap between the straight edge and the left table(the part that does not move)
 
mastercabman said:
wnagle said:
I don't understand where your gap is.  Can you post a pic?
Click to expand...
You can see it in the video.When he puts a straight edge on the miter table,there is a gap between the straight edge and the left table(the part that does not move)
Click to expand...

I think the saw was designed to be like that.
Maybe not quite that much but some at least.
 
What you can't see is what is the high spot or the fulcrum that the straight edge is sitting on.  If the high spot is warped plastic insert throat plate, then it just needs replaced.  

If the Magnesium bed of the turntable isn't flat (easy to check) or goes out of being coplanar when turned,(also easy to check) then the saw has a problem and needs replaced.  

I suppose If the saw were dropped or damaged in shipping and the bolt that the turntable spins on was not perpendicular to the surface of the turntable, that might cause the table to tilt when changing the miter angle.  It's hard to tell what the problem really is from the description.  Either way, if the saw isn't right, let Festool replace it.

 
wnagle said:
 However if that's not the problem, Festool will make it right
Click to expand...
that may be true But he is not in the US

wnagle said:
or you can get a refund within 30 days since you just got it.
Click to expand...
That is probably not true.
Do you know what the Norwegian or EU Festool policy is? [unsure]
I can see nothing suggesting a refund within 30 days. [unsure]
 
On a more positive note, I thought the quality of the video from your cellphone was quite good...
 
I suppose Festool has different warranty policies in different Countries for sure.  Doesn't change the bottom line.  If it's defective, eiden will need to deal with Festool with the warranty he has.  If it's a simple fix like a raised throat plate then the fix will be simple.

My purpose in answering eiden's post was to help him determine if he had a problem and what options he may have in fixing it.
 
Well Eiden I had the same problem. I returned my first and second kapex. I talked with Shane Hollan from Festool he hooked me up with Lester in Festool's service dept. Lester pulled my third kapex from stock and inspected it before shipping it to my Festool rep. Finally this one is level. So far it is a keeper
 
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