Flex Problems, NOOOOOOOOOOOOOO!

Excessive Detail

Excessive Detail

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This is a warning to all who use the flex. So I was buffing a car today and it had some paint marks on it from a little hit and run, so I started to put some pressure on the flex. Everything was going fine until I started to notice what I thought was compound dust, but it actually turned out the be plastic dust and smoke. Apparently putting pressure on the flex caused the backing plate to rub up against something in the head of the flex, I can't really tell what, but I kept buffing and backed off, but I could still smell the plastic burning and then a thin circular peice of plastic came off from between the backing and head of the flex. I guess when I put pressure on it it caused it to tear the plastic and just kept tearing, luckly my flex still works fine, still smell a little funny, I'll take a closer look at it tommorrow, so basically be careful not to put to much pressure on your flex when using it.
 
Never had any problem like you mention with my Flex, but then again I never had to lean on it either. I'll be watching to see if anyone raises their hand with a like situation. Thanks for bringing it to our attention.
 
Excessive Detail said:
This is a warning to all who use the flex. So I was buffing a car today and it had some paint marks on it from a little hit and run, so I started to put some pressure on the flex. Everything was going fine until I started to notice what I thought was compound dust, but it actually turned out the be plastic dust and smoke. Apparently putting pressure on the flex caused the backing plate to rub up against something in the head of the flex, I can't really tell what, but I kept buffing and backed off, but I could still smell the plastic burning and then a thin circular peice of plastic came off from between the backing and head of the flex. I guess when I put pressure on it it caused it to tear the plastic and just kept tearing, luckly my flex still works fine, still smell a little funny, I'll take a closer look at it tommorrow, so basically be careful not to put to much pressure on your flex when using it.
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Yeah, I've noticed that too. I was buffing out swirls out of Maxima, and could smell burning plastic...
 
Its still relatively new so there will be problems with it. I just cant buy any new buffer without seeing how it holds up. Thats why I love my good old dewalt. Maybe they will have a recall on all the flexes that were sold?
 
Excessive Detail check your hex screw on the backing plate and make sure it's not loose....when I got my Flex, all the screws on mine needed to be tightened. If the backing plate is loose I could see it causing excessive rubbing when pressure is applied.

With that being said, I can see if you do apply pressure on an angle (using the edge of a pad) that it can cause the backing plate to rub too.


When I was testing the Flex I did apply pressure and never experienced any "plastic burning". I don't normally use pressure with it though...if I need more cutting, I just slow down the passes.



Lasthope05 said:
Its still relatively new so there will be problems with it. I just cant buy any new buffer without seeing how it holds up. Thats why I love my good old dewalt. Maybe they will have a recall on all the flexes that were sold?
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The Flex 3401 is new but not that new....IIRC, the Flex XC 3401 was released over a year ago.
 
I doubt this is an indication of a flaw with the Flex...JMO
Double check the BP hex screw as mentioned
Did you lean on it at an angle, or while it was flat?
 
I think I read somewhere that there was a backing plate problem on some of the initial machines and they did not release any more until they fixed the problem. I used my Flex for the fist time yesterday and I must say I love the machine.
 
Gary Sword said:
I think I read somewhere that there was a backing plate problem on some of the initial machines and they did not release any more until they fixed the problem. I used my Flex for the fist time yesterday and I must say I love the machine.
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this was related to isolated cases of premature velcro delamination - hence the new BP
 
My question is the same, is this a newer unit or older unit with the original backing plate issues ???
 
ZoranC said:
Kind of design for mating between backing plate and post that Flex uses will allow for some "play" no matter how hard you tighten that screw if offset pressure is used. Check it out.

Still, even with such design it took me decent bit of pressure to make them touch.
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Yes, there is a small amount of play in the backing plate, and if the hex screw is tight, it does take some pressure for the backing plate to touch the machine....but if the screw is loose the backing plate does have more play and if pressure is applied will cause it to rub.


Flex was announced over a year ago but it was not released over a year ago. I do not know exact date when they started shipping in Europe.
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Thanks, I remember hearing about it but wasn't sure.


My question is the same, is this a newer unit or older unit with the original backing plate issues ???
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I'm not sure that would make a difference...the back side of both backing plates are the same except for the diameter (6" and 5.5")
 
Allow me to further think loud (and it is meant as a constructive thinking, it is not meant to be in any way misunderstood or misinterpreted as negative in any way):

I speculate it is too much off center pressure that brings backing plate and housing to touch and that logical response to that would be to say not to use the tool in the manner that it is not designed for.

However, Flex might want to realize that what differentiates great tool design from "just" good one is that great design is proactive and it prevents that from happening.

I speculate this might be easily addressable by increasing distance between backing plate and housing (say by increasing height of geared part of backing plate 1/8" at maximum, or grinding down the housing a little bit, or both; but not thinning down backing plate as that would just make it flex more; LOL, no pun was intended).

Another approach could be taken (but much less easily) by reducing "looseness" by say making contact area between bp and center post wider (wider the area less wiggly T-like contact with single center screw can be) and/or by making metal part in bp thicker so that any variance in manufacturing of that thickness and screw length does not result in screw bottoming out before everything is tight enough.

Just a constructive thought and I hope Flex engineers and powers to be see this and consider it.

In the meantime I will continue using my Flex while paying attention not to use it in incorrect manner even though advantage of that handle (great positioning that allows you to easily apply pressure) is what can also be it's disadvantage (such handles allow for gobs of pressure to end up applied unevenly, as hand is not above the head, it is offset).

If I ever end up experiencing this problem myself I might move position of handle so hand is above the head when pressure is applied. And I might consider finding good CNC place to grind down my housing a bit (while fully aware what that implies).

But not until then.
 
Well I took my Flex apart yesterday and really couldn't find anything wrong with it, I couldn't see were the plastic came off either, the smell is gone, which I figured would happen. I checked all the screws and made sure they were tight, put it back together and tried it again, no problems, I guess I was just putting to much pressure, which I probably didn't need, the Flex itself seems to be enough weight. Overall this experience still doesn't change the fact that this thing is awesome and I wouldn't trade in for anything, its just new to the market so its bound to have a few initial flaws, just take it easy when you guyz get yours.
 
Excessive Detail said:
Well I took my Flex apart yesterday and really couldn't find anything wrong with it, I couldn't see were the plastic came off either ...
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Did you check that thin white teflon-like ring on housing itself?

Excessive Detail said:
... I guess I was just putting to much pressure, which I probably didn't need, the Flex itself seems to be enough weight.
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Flex can take the pressure without problem, but it should not be off-center and uneven and too much. How much is too much? I do not know, I did not measure it when I was trying as I do not have scale (those depression inducing ***tards do not belong in my home) but my wild guess is in excess of 20lbs when off-center. So my wild guess is that it should be able to take 15-20lbs when on center no problem, and that should be sufficient for any work.

Excessive Detail said:
... its just new to the market so its bound to have a few initial flaws ...
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If it is user's error then it is not a product flaw. Product flaw is when product itself is having an issue.
 
I had this SAME problem polishing a vette there was the dust, smell and then the small piece of plastic that fell off.

I was applying pressure tho maybe i need to rethink my process now I am using the flex
 
Dieseldan said:
I had this SAME problem polishing a vette there was the dust, smell and then the small piece of plastic that fell off.

I was applying pressure tho maybe i need to rethink my process now I am using the flex
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Could you please identify area where those pieces came from and take close up pictures of it?
 
I didn't notice the telfon ring, I'll have to take a closer look at it when I get back on land next week, I don't think I exceeded any pressure ranges and I'm pretty sure I wasn't off center or anything like that, I have a few cars waiting on me when I get back so I can play with it a little more.

ZoranC said:
Did you check that thin white teflon-like ring on housing itself?


Flex can take the pressure without problem, but it should not be off-center and uneven and too much. How much is too much? I do not know, I did not measure it when I was trying as I do not have scale (those depression inducing ***tards do not belong in my home) but my wild guess is in excess of 20lbs when off-center. So my wild guess is that it should be able to take 15-20lbs when on center no problem, and that should be sufficient for any work.


If it is user's error then it is not a product flaw. Product flaw is when product itself is having an issue.
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I had the same problem. I was working on a panel when all of a sudden I saw dust and smelled burning and nearly had a heart attack thinking I had just burned through the paint on an Aston Martin. I was applying pressure but nothing crazy. The pad was pretty flat but in all fairness maybe slightly angled due to the panel configuration? Tried tightening the nut after reading this and another post. We'll see if this solves the problem? I did not have any plastic piece come off of mine though and it still works fine.
 
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