New Kapex...broken part

[ekalb]

I got my Kapex/cart/stand a week ago and have been cutting over 1400LF of primed poplar shiplap for a project over the past few days. There have been a lot of compound miter cuts at a ton of different angles. I read about pieces going flying from time to time if the work isn't supported on small cuts. I was really caught off guard by one that happened today. I heard a bang (piece going flying) and then saw broken black plastic. Luckly, it was just the clearance insert, but how the heck can this be avoided? I was worried I dulled the 60T blade it came with a day or so ago, so I picked up the only thing they had in stock at my local dealer which was the 80t blade. The cut quality is about the same, but it was with this blade that I had the issue with.

I have been leaving the saw in the down position until it comes to a stop and I also pull it all the way out towards me before dropping it into the cut. I ordered the Betterly zero clearance insert today and I am hoping that helps the issue.

Any other advice? I'm a little irritated so far, but I do love the saw and the speed I have gained from it.

 

[kevinculle]

A zero clearance insert should largely eliminate this by preventing offcuts from being dragged into the blade slot.  I have the Betterly on mine and, like any ZC insert it becomes wider over time and especially with bevel cuts.  When mine needed attention I used the Fastcap self adhesive ZC inserts over the Betterly.  At 5 strips for $5 it's a good option, although a bit of trimming with an Exacto knife is needed for a good fit.  I like that it highlights the blade area in safety yellow color!

 

[DrD]

Most of my cut-offs are very small pieces, which could fall back & caught by blade.  I just put the FastCap zero clearance tape over the factory piece and works quite well.

 

[glass1]

More proof that this style of blade guard is more dangerous than one than can. E held up by ones thumb. These type of compound cuts with small off cuts and exposed long points tend to hang up guards or small pieces cut pushed by the guard into the blade. Just a poor design.

 

[ekalb]

The Betterly insert solved my issue so far. I have used it for about a week now and have not seen any cutoffs flying around trying to kill me or break parts of the saw. Festool did end me a replacement insert for the right side of mine which took the brunt of the impact, but I don't see any reason why I would put it back in over the betterly zero clearance. I did also receive the tape from fast cap which I will try over the betterly as well to see the results.

thanks for the advice

 

[dfbsone]

i broke the ENTIRE left side, looking at saw, and just received "replacement' part that i must install.  i have a zero insert and zero fence, not real happy about this situation.  i will try to do this!!!!