Ok.. after my visit to the Felder office to have my dado blade checked out, here is what we discovered, and this is what we did to correct the issue.
First off, I learned, was to check to make sure the chippers and outside carbide inserts were seated correctly.? Mine were not..the outside cabinet inserts were fine, but the chippers were set in a way that the back end of them protruded out past the carbide nibblers just a whisper, but that's all it takes for them to create tear-out because they are catching as the "exit" the cut, forcing the fibers of the melamine outward, thus tearing out.? How we st these cutters was to place the dado blade flat on 2 separate pieces of melamine, loosen the set screws (the screws for the chippers are allen type screws and the carbide inserts are the torx type screws) (My high recommendation is to throw that piece of garbage torx tool that comes with the dado set in the trash and get the T-15 torx screwdriver) After you loosen the screws, press down so the dado body is flat and re-tighten the allen set screws.? Yes..I know, you can use a special tool and all that, but we didn't have that and this method worked perfectly fine. Test cut and check the results.?
We also discovered that a slower feed rate gave us a better cut after the bits were set.? My saw is set to run at 5500 rpm. Pictures show how we used the melamine and the results of resetting the bits?
