Kapex stations

[live4ever]

I'm going for the Kapex.  I wanted to avoid the outlay but there doesn't seem to be another saw that satisfies all my criteria...among which are lower/smoother noise and tiny rear footprint.  It's going to live in my shop on a somewhat portable platform but occasionally be schlepped to my parents' house where I'm doing some work.

I was thinking of building a fence system for it using either Kreg or Incra.  Anyone have recommendations?  Any Kapex-specific interface issues?

And as always, feel free to post your Kapex stations!  Thanks!

 

[TomGadwa1]

This is my Kapex station. I have my modified UG Cart and also the extensions. I really enjoy using this setup.
[attachimg=#1]
My station. I have also fabricated a zero clearance cutting platform which in addition to providing zero clearance cuts facilitates cutting very small workpieces safely.
[attachimg=#2]
My zero clearance cutting platform. Recently I cut a 6mm x 40 mm domino to 6mm x 30 on this platform with no undesired results. i. E. offcuts flying away from the saw a MACH3!

 

[live4ever]

Thanks for posting Tom!  I like your small parts rig.  I see you're using those new Bessey auto-adjust toggle clamps.  Definitely need to pick one or two of those up...

Do you take the saw on-site a lot?  Just wondering if that's the reason for going with the UG extensions as opposed to something shopmade?

 

[TomGadwa1]

I use the UG extensions when needed. For me the convenience is being able to have my Kapex stain as small as possible due to the limited size of my shop. When I need to I can easily roll my UG Cart in position and attach the extension or extensions needed to cut longer material. Then when done I stow the extensions away and regain my precious space. I modified my UG Cart to be home based in my shop, but if needed I can revert the stand back to stock configuration if desired. My small parts platform is made of phenolic veneered plywood for stability and accuracy. I assembled it using my FESTOOLS so I would of course get precise results. I purchased INCRA track and cut it to length and milled two channels using my trusty OF1400 router. To cut the material I used my TS55 and MFT3. Then I used my DF500 domino to put it together. Using an accurate square for checking I found the unit I made to accutally be square! I then placed the cutting platform on my Kapex and centered it as best I could. I clamped it in place using two of the Kapex material clamps which holds it well. As you observed I employed the new bessey toggle clamp and it is a gem! The beauty of this clamp is that it self adjusts for differing material thicknesses. This can be adjusted on the clamp using a small hand adjusting screw. So far I love my new cutting platform!

 

[Kev]

My KAPEX+UG+Wings get's stored inside and wheeled outside (under cover) for use. Never goes far though.

Love it!

If I had a bigger space I'd certainly make a "built in" for it.

 

[Mauri Motti]

I have mine placed in my basement workshop with home build (height adjustable) trestle wings/ benches at it's left and right side. No fence though. I thought to have the nessecity to build one and have all what I'd need to build one at home, but I never did. I don't think I really need a fence other then the one that the Kapex has. I do use the apex fences on full extensions at all times. I did though get the MTF Kapex a week or two after I got the Kapex so I can drag it around the house for projects.

I do not however have to carry the saw away from my own house.

[attachimg=#]

 

[JLB builders LLC]

This is my Kapex station. I have my modified UG Cart and also the extensions. I really enjoy using this setup.
[attachimg=#1]
My station. I have also fabricated a zero clearance cutting platform which in addition to providing zero clearance cuts facilitates cutting very small workpieces safely.
[attachimg=#2]
My zero clearance cutting platform. Recently I cut a 6mm x 40 mm domino to 6mm x 30 on this platform with no undesired results. i. E. offcuts flying away from the saw a MACH3!

I need to make a zero clearance like you did. When doing shoe molding I end up using my Bosch beast, the shattering flying pieces at Mach 3 and looking to see if my finger is still there is a little scary to say the least.

 

[sancho57]

I had the same problem with the small pieces shattering and flying all over the place. not only did this scare the hell out of me which caused me to involuntarily react but it was frustrating to.

So what I did was to clamp a piece of 3/4 ply to the Kapex fence cut it 45' both ways and it seemed to solve that problem.

I could of mounted a sacrificial fence permanently to the Kapex as described in the manuel and Gary Katz uses on his DVDs, But I like to remove it when cross cutting I dont want to lose the any of the cutting capacity.

 

[TomGadwa1]

True about not wanting to lose any cross cutting ability. That is why my ZERO Clearance cutting platform is secured temporarily to the KAPEX with the KAPEX hold down clamps on both sides. This makes it easy to remove and install the cutting platform within seconds. Just pull the large trigger on the KAPEX without pulling the second safety lockout trigger, then lower the blade into the kerf line that has been previously cut into the cutting platform. Set the clamps in position and tighten. Raise and lower the saw with the testing use of the large trigger only to verify accurate placement of the cutting platform. This needs to be done to prevent the kerf cut from becoming wider than the kerf of the saw blade. An automatic adjusting BESSEY toggle clamp holds the small pieces to be cut on the cutting platform securely and accurately. When done making the cuts on the small workpieces it only takes about two seconds to remove the cutting platform. Lest I forget it is imperative to insure that the depth limiting lever on the KAPEX is used with the cutting platform such that the saw will not divde the platform into TWO small cutting platforms! Uhg! So my design does not in any way compromise my cross cutting ability and does not in any way require my dearest KAPEX to be violated in any way. I.E. drilling holes in the fences or the table on the saw!
[attachimg=#1]
Photo showing depth limiting lever on the KAPEX saw.
[attachimg=#2]
Photo showing the right side KAPEX clamp holding the right side of the cutting platform.
[attachimg=#3]
Photo showing the left side KAPEX clamp, left side of the cutting platform and the BESSEY toggle clamp.

 

[live4ever]

Tom, in your photos it looks like you've got your cutting platform set slightly in front of the Kapex fence.  Is there any particular reason for that or just the way you happened to secure it when you took the photos?

 

[PaulMarcel]

Really like your setup, Tom; that would be a perfect setup for on-site work.  Great fence setup, too.  I launched a small part (only mach 2.5) while cutting something with a friend nearby.  I didn't react.  He looked at me and cooly asked, "that probably isn't a good thing", "nope, no it isn't".  Someday I'll find it; likely embedded in the garage wall behind something.

 

[TomGadwa1]

Tom, in your photos it looks like you've got your cutting platform set slightly in front of the Kapex fence.  Is there any particular reason for that or just the way you happened to secure it when you took the photos?

Yes there is a reason.
The setting of the depth limit has to do with it. Because of the geometry of the saw when the depth limit is set to keep the saw kerf shallow it also keeps the cutting towards the back of the saw from reaching as far into the fence. To compensate for the limited reach back towards the fence I fabricated some very accurate spacers to move the fence towards the front of the saw. Now the saw cuts completely through the fence on the cutting platform and of course with ZERO clearance. This setup is perfect for cutting small moldings in a safe manner. I also considered making one that could do mitre cuts as well, but for now I am testing the waters so to speak with this simple but I think quite effective cutting platform.

 

[Kev]

Really like your setup, Tom; that would be a perfect setup for on-site work.  Great fence setup, too.  I launched a small part (only mach 2.5) while cutting something with a friend nearby.  I didn't react.  He looked at me and cooly asked, "that probably isn't a good thing", "nope, no it isn't".  Someday I'll find it; likely embedded in the garage wall behind something.

Mrs Tate has never understood why Bugsy didn't come home.

 

[Dan C]

I am a member on a welding forum as well, and I saw this LINK  That is a stand I think I may have to think about duplicating, as mine never leaves the house. 

 

[Alan m]

[attachimg=#]

that pritty sweet dan.
great idea.
i would like it to have folding wings  (or the last few feet maybe).

 

[Dan C]

Yeah- I think that when i make this for myself, the folding wings would be a mod over the OPs design.  I have a couple possible final versions, but that is a pretty cool station.  There is a place not far from me that does anodizing and I am thinking it may get done to match the Kapex itself...