Modifying an FS 5000 rail?

[wow]

I haven't even received my first green goodies yet, but I am so excited I can't stop my mind from racing ahead with all the possibilities, ideas, attachments, and modifications people do and have done.

In the future I am considering getting the Festool 491500 197" Guide Rail FS 5000. Years ago I had a 12 foot piece of steel bar machined flat so that I could use it as a straightedge for various things. I have ended up not using it much because of its weight, but also because it's narrowness (1 1/2") makes it less functional than I thought it would be.

According to Amazon the FS 5000 weighs 45 pounds. Not too much to carry, but enough to make it difficult to handle and move with one hand, or when bending over a sheet to position it near the center. Has anyone machined relief holes into a rail? Kinda like this, but longer and positioned so the relief holes don't interfere with the operation for either cutting or boring:

Holes

Since the holes wouldn't be used for anything other than weight reduction, they wouldn't have to be perfect to thousandths of an inch, but I would certainly want them to appear perfect to the naked eye.

As another idea, has anyone modified theirs to be a "Holy Rail"? i don't know how practical it would be, but DAAAAMN it would look sexy, wouldn't it?

 

[Svar]

Festool rail is about 1.3 kg/m. FS5000 is under 15lb. 45 lb is probably shipping weight with crate.
Either way why reduce rigidity of already rather delicate rail by drilling holes?

 

[Kev]

Interesting idea, but I certainly wouldn't want to be the first person to try it and find out it was actually a bad idea [wink]

... end of your warranty too no doubt !

 

[peter halle]

Like others I wouldn't advise doing that.  Also regarding making a "holy rail", the holes are not circular, so you would need specialized machining.  Unless you have the equipment to do that yourself it probably isn't worth the cost, let alone you probably would never need to have that length of rail in a shelf pin usage.

Peter

 

[wow]

I was sort of wondering how it could weigh 45 pounds, but if that's including the shipping case then I understand and agree that modifying it makes no sense. Sorry for the hair-brained (hare-brained?) idea.

 

[ccarrolladams]

Also, remember that Festool drills all the round holes and mills the Holy Rails before the anodizing process.

When you come along later to add your own holes, they will not be anodized.

I own a 5000mm guide rail. We use it most days to make cuts on 4x10' material. None of us in my shop have the slightest difficulty moving it by ourselves. I certainly does not weigh more than 7.5kg

 

[AlexThePalex]

I don't see what's wrong about making holes in the rail to make it lighter. It is just a light aluminium rail that doesn't bare any weight except its own. As long as you don't turn it into swiss cheese you could easily chip some material away here and there. But as mentioned, the FS 5000 is nowhere near 45 lbs, so it's a non-issue. I also don't see why not anodising it would be problem, it's only aluminium, it won't rust anyway.

 

[ccarrolladams]

Raw aluminum can mark wood in such a way it interferes with finishing. You do not always see the marks until it is too late.

Yes, aluminum does not rust, but it can and does corrode.

If thousands of manufacturers felt they could sell aluminum products without anodizing or other treatments, they would have saved a whole lot of money.

Remember back to pre-1920 before advances in production of raw aluminum, tempering and anodizing turned aluminum into such a useful product.

But, if you want to take a chance with your wood contacting raw aluminum, best of luck. Your mileage will vary.

 

[VictorL]

I'm just wondering. Why do you need 5 meters rail? It's almost 2 stories high.  I do have 3 meter rail, and it is sufficient for cutting sheet goods in two dimensions. If I need to cut 12', I just add another rail.

[attachimg=1]

 

[wow]

I'm just wondering. Why do you need 5 meters rail? It's almost 2 stories high. 

I am not sure that I NEED it at all, but that has never stopped me - nor apparently a lot of folks on this forum judging by the number of - say - sustainers they possess?!

[eek]

I do like to keep a nice long straightedge around, and a 6' Starrett straight edge is $500+!!! It seemed that this would fit the bill nicely for anything I do, plus serve its intended purpose as an extra-long rail when I need one. I can see it coming in handy for trimming the ends of subfloor on new construction or on outdoor structures likes decks and the like.

 

[festnoob]

I'm just wondering. Why do you need 5 meters rail? It's almost 2 stories high.  I do have 3 meter rail, and it is sufficient for cutting sheet goods in two dimensions. If I need to cut 12', I just add another rail.

[attachimg=1]

What are you working on? Looks good.

 

[jimbo51]

There have been posts regarding the long Festool rail being less than straight. The Starrett is likely to have a much tighter specification in that regard.