View source for Projets:Perso:2018:KAPEX KS120 DadoCutFunctionEnhancement


{{Project
|name=: Modify / enhance the dado cut adjustment span of the FESTOOL Kapex KS120 miter saw
|author= Eric
|proposal_date=August 2018
|abstract1=Mod for FESTOOL KAPEX KS120 MITER SAW 
|abstract3=Augmentation de la plage de réglage de la fonction de découpe de rainure de la scie à onglet FESTOOL KAPEX KS120
|tags=FESTOOL KAPEX KS120,dado cut,rainure,modding,enhancement
|where=
|for_who=my Kapex
|official_electrolab_project=
|elecrolab_project_manager= N/A
|budget= 15€
|number_of_members= N/A
|estimated_time= 1/2 day
}}


=Dado cuts height adjustement feature=

The Kapex KS120 height adjustement for dado cuts is limited to about 40 mm, which avoids using this feature for high workpieces.
This limitation [http://festoolownersgroup.com/festool-how-to/kapex-ks-120-cutting-depth-limiter-limitation-of-cutting-higher-workpieces/ seems to annoy other Kapex users.]

[[File:FESTOOL_KAPEX_dado_cut_mod_50411.JPG|800px|thumb|center|Dado cuts are limited to about 40 mm]]


Ron Paulk recorded a [https://www.youtube.com/watch?v=YynWuNeGuQY small video] to show how to perform dado cuts using the Kapex KS120. Many thanks to him !

=User's manuals=
The cutting depth limit lever is referenced at position "1.4" on page 4 of the [https://www.festoolusa.com/-/media/tts/fcp/festool-usa/downloads/manuals/472068_005_ks_120_usa.pdf#page=4 PDF user manual.]

The cutting depth limit lever is referenced at position "U" on page 7 of this [https://www.manualsdir.com/manuals/103754/festool-kapex-ks-120.html?page=7&original=1 very nice official Kapex KS120 supplemental user's manual.] 

=Enhancement=

I updated my Kapex KS120 to allow a cutting depth limit adustement from 0 to ...93 mm

==How to ?==
Replace the existing cutting depth limiter lever with a custom made part.

To unmount the existing 1.4 lever, remove the mains cable strain relief and the machine back panel/plate.

As shown in the picture below, the cutting depth limiter lever is of easy access.
[[File:FESTOOL KAPEX dado cut mod 50412 ann.jpg|800px|thumb|center|The cutting depth limiter lever is easy to replace]]



On a lathe, process a [https://www.rcm-machines.com/fr/c45k-poli-/acier-c45k-rectifi-h6-rond-poli--6-mm-x-300-mm/rcstp06 6 mm silver steel rod] or similar to make a modified copy of the lever 1.4 using the dimensions shown in the picture below (scale = mm). The shape of the thinner side of the rod does not need to match exactly with the original part.

[[File:FESTOOL KAPEX dado cut mod 50409 ann.jpg|800px|thumb|center|Original and custom made cutting depth limiter levers]]



Use an M6 x 1 mm (right hand) HSS die to machine the thread.

e.g ref. SDEMM06B [http://www.tap-die.com/contents/en-uk/p637_6x1mm_dies_1od.html here.]


The total lenght of the new custom lever should not exceed 11,5 cm, as shown in the picture above.
  
Use an angle grinder to create the two flats on the opposite side of the thread.



Mount the barrel nut on the threaded side of your custom made lever

As you can observe on the original part, the lowest possible position of the barrel nut is 12 mm.

On your custom made lever, use a small chisel to break the thread at 3 or 4 locations in order to limit the barrel nut lowest position to 12 mm (same value as on the original Festool part).

[[File:FESTOOL_KAPEX_dado_cut_mod_50417.JPG|800px|thumb|center|Limit the barrel nut lowest position to 12 mm. The broken thread is visible just at the right side of the barrel nut]]


Replace the original lever with your custom made lever.

Once mounted in your miter saw, check if your custom made lever has enough room to move near the motor enclosure.

[[File:FESTOOL_KAPEX_dado_cut_mod_50420.JPG|800px|thumb|center|Take care of the motor enclosure]]

==Mounting hints==

Keep a look on the tall miter latch parts to be sure they are in their correct position.
[[File:FESTOOL_KAPEX_dado_cut_mod_50421.JPG|800px|thumb|center|Tall miter latch parts mounting]]
 

While positionning the plastic back panel, take care to put the tall miter locking lever spring into it's groove.
[[File:FESTOOL KAPEX dado cut mod 50424 ann.jpg|800px|thumb|center|Spring and groove for the tall miter feature]]

==Results==
With this modding, we now obtain a gorgeous adjustement span from 0 to 93 mm.
The dado cut feature of the Kapex becomes now far more versatile.
[[File:FESTOOL_KAPEX_dado_cut_mod_50435.JPG|800px|thumb|center|Great! We now have more than twice the span of the unmodified machine]]

=Other hints and limitations=
==Barrel nut==
You may use the M6  x 1 barrel nut from the existing lever assembly or buy a [https://www.fastenright.com/general-fixings/cross-dowel-barrel-nut/ff04 new part] 
The original part has a 10 mm diameter and 14 mm lenght.

==The height adjustment lever has now 3 positions==
Once upgraded with your custom part, setting the depth position is slighly different.

For adjustement limit above 50 mm, the 1.4 lever has to be set into an intermediate position.

[[File:FESTOOL_KAPEX_dado_cut_mod_50436.JPG|300px|thumb|left|Depth limit lever in engaged position for dado cuts from 0 to 40 mm]]
[[File:FESTOOL_KAPEX_dado_cut_mod_50442.JPG|300px|thumb|right|Depth limit lever in disengaged position]][[File:FESTOOL_KAPEX_dado_cut_mod_50428.JPG|300px|thumb|center|Lever in intermediate position for dado cuts from 40 to 93 mm]]



==Cutting witdh==
Another limitation (that already exists on an unmodified Kapex saw) : you won't be able to perform the dado cut in one pass on the full nominal machine width of 305 mm, but 220 mm seems to be reachable. To process wider dado cuts, you need to reverse your workpiece.