Festool PD561432, PM561556 Guide Rails, Tips for Choosing Guide Rail Lengths, Joining Rails

Guide Rails

Guide rails come in a variety of lengths, ranging from 32 inches to 197 inches (800mm to 5000mm). It is always best to use the correct length rail for the cut, but sometimes it is necessary to join two smaller rails together to make a lon- ger rail. Guide rail connecting bars are available for joining two or more guide rails together.

►► Shorter guide rails are easier to work with for shorter cuts. A cabinetmaker, for example, may want dedicated shorter guide rails for crosscutting cabinet carcase components.

Tips for Choosing Guide Rail Lengths

The length of the guide rail must be at least 10 inches (250mm) longer than the cut to be performed. This is so that the saw can be supported (and guided) at both the beginning and end of the cut. The minimum position is when the guide rail cam (page 7) is at the edge of the rail, but still on the rail.

►► The guide rail must extend at least 6 to 7 inches (depend- ing on blade depth) ahead of the cut to allow the saw- blade to be plunged without entering the workpiece.

►► The guide rail must extend at least 3 inches past the cut to allow the center of the blade to exit the workpiece.

To simplify storage or transportation, some woodworkers prefer having two shorter rails instead of a longer rail. Other woodworkers prefer to have single lengths for the specific cuts they make, to minimize the frequency of needing to join rails. Here are some tips about choosing guide rail lengths to suit your needs:

►► For frequent cutting of plywood sheets that involve both ripping and crosscutting, dedicated guide rails of the appropriate length may be best. This allows for switching back and forth quickly without having to join rails.

►► It’s more efficient to have guide rails of different lengths than it is to have two guide rails of the same length. This gives you more variety in lengths. For example, if you had two 55 inch rails, you would have only two possible combinations: 55 and 110 inches. However, if you had lengths of 42 and 75 inches, for example, you would have three combinations of lengths: 42, 75, and 117 inches.

Minimum

Position at the

Start of the Cut

Minimum

Position at the

End of the Cut

Center

of Blade

Joining Rails

Note: Do not assume that butting the two rail ends together will result in a straight line for their entire length. A very tiny error in the butted joint can result in a significant error across the length of the joined rails. A long straightedge is the recommended method for aligning the rails.

1.Insert the two connecting bars into the T-slots on one rail (typically the longer of the two rails). Make sure the clamping screws are facing outward.

2.Slide the second rail over the connecting bars and push the two rails together.

3.Place a straightedge across the joint between the two rails, as shown to the right.

4.Center the top connecting bar across the joint, and gently tighten the 4 clamping screws. Do not over tighten the screws, or you may dimple the guide rail.

5.Carefully flip the guide rails over, and with the straight- edge across the joint, tighten the bottom clamping screws.

Upper

Connecting

Bar

Straightedge

Lower

Connecting

Bar

Clamping

Screws

Supplemental Owner’s Manual 11