Kapex KS 120 EB Zero Clearance Insert Block - 3D Printable

[ryanjg117]

Thought I'd share a new, simple "zero clearance insert block" for the Festool Kapex KS 120 EB. I remixed this from Dudadz3d's original model that fits the Kapex KS 120 REB.

Why is this cool?

• Doesn't require any modifications to the Kapex original fence
• Doesn't require an auxiliary fence and its drawbacks (thicker auxiliary fences interfere with the Kapex swiveling clamps)
• Is easy to install and remove, and retains an exact position when re-installed

Download and print your own:

Zero Clearance Block/Backplate Festool Kapex KS 120 EB by Ryan G | Download free STL model | Printables.com

Zero clearance fence insert for the Kapex KS 120 EB compound miter saw. | Download free 3D printable STL models

www.printables.com

Just be sure to check the model of your Kapex before printing. We discovered the fences are slightly different between the REB and EB models (specifically, the "ear" locations).

 

[smorgasbord]

These kinds of zero-clearance fence blocks are great. I have a modified setup on my Bosch slider. This is cool compared to the Colliflower in that you don't have to buy an expensive fence replacement.

Looks like it can't go far in terms of bevel cuts, though. But does look like a modified version that is a vertical "V" shape might still clip onto the fence when spread further out.

 

[ChuckM]

Very simple design. Do you have any idea how much it affects the dust collection? Could you show a picture of it by itself before installation? I don't have a 3-D printer but may be able to fashion one out of wood.

 

[ryanjg117]

Good point on the beveled cuts - that would require the fences to be set apart quite a bit more, and the block to be widened as well. I very, very rarely do bevel cuts, so it's not worth the redesign or added filament cost for me. But if there's strong interest in making one, I could be persuaded to take the time to remodel it.

As for impact on dust collection, not sure yet. My rubber dust shroud seems to just barely glide over it when the blade is all the way down, so at least it won't bind up the motion of the cut.

 

[smorgasbord]

I don't know about this fence ZCI on the Kapex, but I can say on my Bosch it actually helps dust collection since the slot in back helps channel dust to the dust collection boot all of these saws have.
However, if you have an aftermarket dust collection boot, like those sold by ShopNation, there is interference and you have to give one of them up. The boot hits the ZCI unless it's not very tall. Might be OK if you only cut 4/4 stock flat, but that's not what I exclusively do.

 

[ChuckM]

I found someone who would make the zci block for me with his 3d printer -- for $10 Cdn. It's a much better deal than trying to make one myself out of wood!

 

[ChuckM]

Thanks to Ryanjg, I now have three ZCIs (yellow one a prototype). I just learned that the 3D-printer owner started having his printer last Christmas and has been making many many things, such as the little springy cat.

 

[ryanjg117]

Thanks to Ryanjg, I now have three ZCIs (yellow one a prototype). I just learned that the 3D-printer owner started having his printer last Christmas and has been making many many things, such as the little springy cat.

Nice! Yep, I've been finding a lot of excuses for 3D printing. Those blocks look great.

I'm chatting with the original designer now about the possibility of creating an enlarged version which would also work for +/-45 degree bevels. TBD for now.