Author Topic: Replacing a Cross Stop Part on DF 500  (Read 276 times)

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Offline bohaiboy

  • Posts: 28
Replacing a Cross Stop Part on DF 500
« on: July 03, 2022, 12:58 PM »
Hi all, I accidentally knocked over by base that had the cross stops attached.  Well needless to say the concrete floor won the battle and broke off one of the stops, breaking the wedge connector in to three pieces.  The remainder is good.  SO being an engineer I took the good side apart to see how it was assembled.  It is  pretty simple with there being a cam on the lead bolt that as it is turned, moves the wedge to a tighter position thus securing it to the DF 500.  I am having difficulties in alignment such that when I turn the handle, it secures the cross stop tightly.  Any suggestions or hints?  I an sure someone on here has had the issue before.

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Offline Chris Wong

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  • Posts: 1000
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Re: Replacing a Cross Stop Part on DF 500
« Reply #1 on: July 03, 2022, 02:03 PM »
I believe you need to take off the levers (part 3) and reposition them on the cam so that proper tension can be achieved. I recall that there are six possible positions for the lever to be installed... only one is right :)
Chris Wong, http://FlairWoodworks.com and https://www.ultimatetools.ca/
First Festool was a free pencil.
Shipping live-edge cribbage boards around the world since 2010.

Offline Crazyraceguy

  • Posts: 1667
Re: Replacing a Cross Stop Part on DF 500
« Reply #2 on: July 03, 2022, 06:27 PM »
You are probably lucky that the cross-stops were there to cushion the blow. I know of at least two DF500 base/fence units that met the concrete at the speed of gravity, neither survived it initially. They were repairable but had to go back to Festool. One of them was the demo unit at my local dealer. He told me about it the day I bought mine and I have been extra careful with mine ever since. I unplug the cable and hose every time I set it down. One kick of either could send it to the same fate, if they were connected.
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