Kapex

[henry1224]

When I got the kapex I unpacked the unit, looked it over and put it away until I read the manual.
I finally got around to using it over the weekend. I noticed that the insert plate was not flush, it stuck up "arched up" about an 1/8 of an inch on both sides.
Looking at the videos on the festool web site, the plates showed up as flat and smooth.
Has anyone experienced this problem on the new Kapex?

I went back to woodcraft and they replaced the inserts and now the plates are flush

 

[MiterMaster]

...I noticed that the insert plate was not flush, it stuck up "arched up" about an 1/8 of an inch on both sides...

Are you talking about the black, plastic blade clearance inserts?  The ones on my saw were flush when I got the saw, but over time stood a bit proud, my opinion is that they warped.  Anyway, a quick fix is to just toss them out and make your own zero clearance insert from wood - this is what I did.  My cuts are better too, since the wooden insert only allows clearance for the blade and nothing else.

Mike 

 

[Brice Burrell]

The issue is that the inserts expand/contract when exposed to heating and cooling. When the inserts expand they can bow upward as they contact the edges of their recess. You can enlarge the holes and trim a small amount of the ends of each insert. This will allow the inserts to be able to move freely and not bow. 

 

[rnt80]

Seriously?  I've read quite a few of your posts, Brice so I trust your level of product knowledge.  Another problem with this tool?  I've only had two other CMS, a  Ridgid and a Bosch and I never had an issue like this with the insert.  I never expected this saw to float on air but the number of issues that have developed seems to be beyond what should be acceptable.

 

[Frank-Jan]

...  Anyway, a quick fix is to just toss them out and make your own zero clearance insert from wood - this is what I did.  My cuts are better too, since the wooden insert only allows clearance for the blade and nothing else...

Does the zero clearance insert affect dust collection? I assumed they designed those inserts the way they are to have better dustcollection, instead of making them adjustable like the ones on my makita (I didn't use the feature much, too much hassle for me, grabbing a screwdriver every time you need to make a bevel cut) I guess it would be possible to modify the kapex insert into zero clearance inserts, like the ones on the makita, (elongate the holes for the screws), but it would be even more hassle to adjust, since they are held by 3 screws each, vs 2 on the makita)

 

[Brice Burrell]

Seriously?  I've read quite a few of your posts, Brice so I trust your level of product knowledge.  Another problem with this tool?  I've only had two other CMS, a  Ridgid and a Bosch and I never had an issue like this with the insert.  I never expected this saw to float on air but the number of issues that have developed seems to be beyond what should be acceptable.

MT, I've not had any real problem with the inserts but I remember some else posted this "fix". I should have mentioned this in my post above, I didn't mean to take credit for this fix.

Like you, I've never had issue with the inserts of my other saws, but it seems the Kapex inserts are giving some people trouble. Some have broken when cutoffs get caught in the blade.

A plywood zero clearance insert sound like a good idea.

 

[MiterMaster]

Another problem with this tool?  I've only had two other CMS, a  Ridgid and a Bosch and I never had an issue like this with the insert.  I never expected this saw to float on air but the number of issues that have developed seems to be beyond what should be acceptable.

Mr Alarmist here, I would not classify this as a problem.  All my other miter saws had the same flimsy plastic inserts, just toss them away and make your own zero clearance out of wood.  Also, the way I made mine, not super snug, but snug enough to stay in place, I did not use any screws to hold it in place, and it has not given me any trouble.

Mike

 

[MiterMaster]

Does the zero clearance insert affect dust collection?

I have not noticed any less dust collection with the zero clearance insert, it still collects very well.  In fact, I would tend to think it would collect a bit better because of the tighter tolerance of the insert.  Another plus, you don't get those tiny slivers that often fall below the plastic inserts as there is only room in there for the blade.

Mike

 

[Brice Burrell]

Mr Alarmist here, I would not classify this as a problem.  All my other miter saws had the same flimsy plastic inserts, just toss them away and make your own zero clearance out of wood.  Also, the way I made mine, not super snug, but snug enough to stay in place, I did not use any screws to hold it in place, and it has not given me any trouble.
Mike

Mike, I don't think I'd trust that, I'd screw it down. This could be a safety issue. If the insert gets caught up in the blade and kicks back into the motor housing solid wood could splinter and that'd be ugly.

 

[MiterMaster]

Mike, I don't think I'd trust that, I'd screw it down. This could be a safety issue. If the insert gets caught up in the blade and kicks back into the motor housing solid wood could splinter and that'd be ugly.

Your point is well taken, after reading your statement I thought to myself, yeah that was pretty dumb of me not to secure it down with screws.

Mike

 

[alanm]

Yep, my inserts also warped after a hot spell followed by a cold spell. A bit of trimming with a knife and some brute force screwing them down temporarily fixed it.but it comes back like a humped back whale.

This is fault four that I'll also get fixed under warranty. (after mitre lock, laser and fence faults)

I'm hoping they recall them and offer full refunds as I'm getting a little tired of the questionable quality. It's just like my Loewe TV (also German) all over again..... 

Hey at least the motor still works and it cuts wood OK.
It's still a good saw, but not worth the price given the many issues.

 

[Brice Burrell]

Yep, my inserts also warped after a hot spell followed by a cold spell. A bit of trimming with a knife and some brute force screwing them down temporarily fixed it.but it comes back like a humped back whale.

This is fault four that I'll also get fixed under warranty. (after mitre lock, laser and fence faults)

Alanm, I'm sure Festool will send you new inserts but I don't know if you'll be happy because the new inserts may well do the same thing. I personally don't see the warped inserts as a problem, at least on my saw. Maybe your inserts are doing something different than mine?? I think there's good advice here as to how to solve this issue, if that isn't good enough, you can always return the saw and get your money back.

 

[nickao]

I don't think I ever purchased a miter saw where I used the stock insert very long. I usually buy a Forrest blade first thing and then make a zero clearance insert next.

I think a company that included two inserts , one zero clearance for the blade they provide would be a neat feature.

Also many times I wished the miter saw were offered with no blade at all, reducing the price. I never had a new miter with a blade and insert I liked out of the box.

Maybe one or both of these this ideas could be implemented by Festool

 

[pierreblonde]

mine was the same to , just make a insert there better anyway

 

[justinmcf]

hi henry1224, i live in the gold coast, queensland, australia. it gets warm here, very warm.

within a week of buying the kapex last october, the plastic plate started to swell up, i took it out, and threw it in the bin with disgust.

never had this problem with a makita, then i cut up some forest red gum and made my own plates.

took me 15 minutes to make 3, i highly reecommend you do the same, it looks cool too!