Track Rail 2.2mm Kerf Offset Tool

thingiverse

Frustrated again by the track saw's finicky track positioning when cutting small pieces from larger stock, I recalled a clever aid shown in the "10 Minute Workshop" on YouTube by Peter Millard.\r\n\r\nThe problem lies in using the plastic strip along the edge of your track rail to perfectly align with your cut line, with the piece you want to keep located under the rail. This results in the blade's kerf fully positioned in the waste area, while the plastic strip helps minimize tearout. This works well when cutting pieces as wide or wider than the rail itself, allowing for full support of the rail and easy clamping.\r\n\r\nCutting strips thinner than the rail poses problems, requiring a second piece of stock under the rail to support the back and ensure the rail is flat against the stock being cut. Additionally, Festool-style rails have their clamping slot towards the rear, making it difficult to clamp to the stock being cut, and often losing secure connection between the rail and stock.\r\n\r\nThe MFT table helps with some of these issues, but picture a scenario where you have a full 4x8 sheet of heavy birch ply, and want to cut a 10mm strip along its entire 2440mm length. You can't hang the rail out in space with just the lip touching the sheet; flipping it around so it's supported by the sheet requires compensating for the kerf (2.2mm) when marking your cut line, which is a hassle.\r\n\r\nThis little 3D printed device makes this entire process much easier. Mark your cut lines as usual, then place the rail on the other side of the cut line than traditionally used, and slide this under the plastic lip with the 2.2mm bar snugly against the edge. Line up the line to the dingus, and it compensates for the kerf without any measurement compensation. The plastic strip is no longer protecting the piece you're cutting from tearout, but there's a replaceable sacrificial part for Festool track saws that helps with that (I wish it was better designed to deal with different plunge depths).\r\n\r\nThis solution may not be complex, but if you've encountered similar frustration and have access to a 3D printer, give it a try and see if the small cost of plastic is worth it.