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The accessories used for fence shaping are: (A) shaper fence,
(B) feather board guard, (C) shaper insert, (D) shaper arbor
and cutter and (E) dust chute.
between a plain edge and shaped one is often enough to elevate the
beauty and elegance of the simplest project. The shaper not only
makes it possible to embellish otherwise square, plain edges, but
it also has practical applications as well. Among other things,
you can form the parts of a drop leaf table joint, do drawer joints,
make a tongue-and-groove joint, shape half-round or curved moldings,
and so on.
The Mark V
becomes a very efficient shaper when it is in the drill press mode
and equipped with the special shaper accessories (Figures
9-1 and 9-2).
The shaper insert should always be used to provide maximum support
for the work around the cutting tool. For fence shaping the shaper
fence is secured to the table. Both fence boards are adjustable
endwise and front to back, so the opening for the cutters can be
kept small for safety. The infeed board is screw-adjusted for depth
The accessories used for pin shaping are: (A) circular shield
and brush, (B) pins, (C) shaper arbor and cutter, (D) shaper
insert and (E) dust chute.
cut. Pins that
are screwed into the shaper insert are used for pin shaping.
Before using the shaping accessory, read and understand the following
There are two
major factors to consider about the safe operation of the shaping
accessory: the speed and the sharpness of the cutter. Remember that
the faster the speed and the sharper the cutter, the smoother the
danger zone extends 3" out from cutter in all directions. Work cautiously
and slowly, especially when shaping against collars. Working this
way will not only keep your hands safe, but will also increase the
quality of your output.
the Shaper--Shaper guards must be used for all shaping operations.
The fence guard is mounted on the shaper fence and the feather board
guard is mounted to the quill when fence shaping. The feather board
guard is adjustable to accommodate various thicknesses of stock.A
feather board is used to hold stock up to 6" wide against the fence.
shield and brush assembly is mounted on the quill when pin shaping.
The shield is adjustable to accommodate various thicknesses of stock.
- Wear proper
eye and ear protection.
- Always use
the shaper insert.
- Wear a dust
mask or connect a dust collection system to the dust chute. Keep
the dust chute mounted to the shaper insert even if you do not
have a dust collection system. The chute guards the cutter below
the table. You can collect dust and chips in a trash receptacle
positioned beneath the table.
- Tuck long
hair under a hat or tie it up. Do not wear ties, gloves, jewelry
or loose cloth-ing. Roll sleeves up above your elbows. Wear nonslip
- When mounting
cutters and collars, make certain that the tongue washer is correctly
installed and directly under the hex nut and that the nut is tight.
Also that the arbor setscrew is tightened against the flat of
- Be sure the
cutter(s) is positioned with the cutting edge facing to the left.
o Listen for chatter or signs of looseness at start-up. If you
hear, see or suspect problems, turn off the power and unplug the
machine. Correct any problem before proceeding.
- Keep cutters
clean, maintained and sharp.
- Operate the
shaper at speeds between "U" (4400 RPM) and "Fast" (5200 RPM).
- When edge
shaping, always use feather boards to guide the workpiece.
- When shaping
the end grain of stock 2" to 6" wide, use your miter gauge with
safety grip to control the stock, and keep the feather board guard
in place to protect your hands and hold the stock down. Do not
shape the end grain of stock less than 2" wide.
- Always feed
the workpiece from left to right against the rotation of the cutter.
Otherwise a kickback will occur.
- Use a push
stick to feed a narrow workpiece. When it is necessary to push
a workpiece underneath the feather board guard, use a long piece
of scrap wood.
- Avoid taking
deep cuts. If the amount of material to be removed is substantial,
make more than one pass. Set the fence to make a partial cut and
then readjust the fence accord-ingly to reach the final shape.
- Cut with
- Do not stand
in line with the workpiece being fed. In the event of a kickback
you could be hit.
- Feed the
workpiece slowly. Use extra care in shaping workpieces that contain
figured grain or knots, as these may cause kickbacks.
- Always feed
the workpiece against the rotation of the cutter, left to right
in front of the cutter, right to left if cutting with the rear
of the cutter. Otherwise a kickback will occur.
- Always use
at least one push block to help control the workpiece. Use two
- Always use
the left starter pin. Use the right pin whenever possible.
- Hold the
workpiece firmly against the left starter pin and feed the workpiece
slowly into the cutter.
shaping, i.e., the shaping of the edge of a hole or small opening
(less than 6" in diameter) in any shape, should not be attempted.
Three-lip shaper cutters are available as combination cutters,
full-profile cutters, or in sets that form the mating parts
of a particular joint. *Warning: always use the fence assembly
when using these cutters that remove the entire workpiece
edge. Click on image to view larger.
maintain a complete assortment of cutters can be expensive. A careful
selection of from ten to twenty shapes (Figure
9-3), picked for the type of work you do, is adequate. With
a basic assortment on hand, you can always add a new cutter as the
need for it arises.
most practical type of shaper cutter for home workshop use is the
three-lip shaper cutter shown in Figure
9-4. This type of cutter is available in a great variety of
shapes: some are combination cutters, others have a profile that
will produce a particular shape such as a tongue or groove. Other
shaper cutters come in sets so mating parts can be cut (Figure
Exambles of three-lip shaper cutters.
Examples of cutters that should be purchased in sets. At the
top, tongue-and-groove cutters. The others are mating cutters
for the dorp leaf table joint.
The shaper arbor
holds standard shaper cutters and collars (Figure
9-6). The arbor is locked firmly in place by securing its setscrew
against the spindle's tapered flat. The collars are used for depth-of-cut
control and for cutter spacing. The cutters and collars are secured
to the arbor with a nut. Be sure the nut is tight before starting
(A) The shaper arbor and (B) various collars.
for cutter height, make the major adjustment by raising or lowering
the table. The final setting is made with the quill feed lever.
On shaping operations, especially at high speeds and on hardwoods,
quill extension should be held to a minimum.
Combination cutters can do various jobs. (A) Here a quarter-round
and cove cutter is used to round off the edge of a workpiece.
(B) The same cutter is shown forming a cove.
It is not usually
desirable to use the full shape of the cutter to form a molding.
How one versatile cutter is intended to be used is partially described
and shown in Figure
A wide variety
of shapes can be made by changing one or more of the following:
- The depth
of cut, which is adjusted by moving the table or the fence or
by using collars.
- The height
of the cutter in relation to the work, which is controlled by
the table or the quill feed lever.
- The position
of the work when making the pass.
One combination cutter, in this case a bead and a quarter-round,
can produce many shapes. Some forms are done with one pass,
others require two or more passes.
9-8 shows a few shapes formed by a single cutter; in this case
a combination cutter that can be used to shape a bead or two sizes
of quarter-round was utilized. Some of the shapes were cut in a
single pass, others required two or more passes, but the same cutter
was used every time.
thing to remember is that not all cutters are intended to cut their
full-profile shape, even though they can be used that way. Most
of them are combination cutters.
Collars are used above, below, even between cutters as controls
for depth of cut and, when doing pin shaping, to provide bearing
surface for the workpiece.
in various sizes and are used to control the depth of cut and to
position the cutter. As shown in Figure
9-9, they may be set over, under or between cutters. Be sure
to position the keyed washer so it seats correctly in the arbor
slot. Never set up cutter/collar assortments that don't allow the
arbor nut threads to be fully engaged.
Since the collars
lock on the arbor together with the cutters and turn at the same
speed, there is the potential, when the workpiece bears against
them, of scoring or even burning the workpiece. Keep the collars
clean, smooth, and free of knicks and burrs. When cutting, hold
the workpiece against the collars with just enough pressure to maintain
One combination cutter, in this case a bead and a quarter-round,
can produce many shapes. Some forms are done with one pass,
others require two or more passes.
cutters should be respectfully cared for. They are an investment,
and they work best when they are clean and sharp. They can be kept
in the plastic cases they are packed in, but selecting the cutter
you want will be more convenient if you make the case shown in Figure
9-10. It will hold up to 30 cutters, or you can use some of
the dowel posts for storing the collars. Use gummed labels near
each post to identify the cutter. Construction details for the case
are shown in Figure
9-11. Cutters should be carefully cleaned before storage.
Construction details of a shaper cutter storage case.
The width of the stock determines the setup.
When fence shaping
the width of the stock determines the position of the stock and
the shaping accessories used:
- Stock less
than 1" wide, use the feather board guard, one feather board on
the infeed side and an additional feather board on the outfeed
side, secured in the table slot (Figure
9-12A). Use a push stick or when it's necessary to push stock
underneath the feather board, use a long piece of scrap wood.
- Stock 1"
to 2-3/4" wide, use the feather board guard and a feather board
secured in the table slot (Figure
- Stock 2-3/4"
to 6" wide, use the feather board guard and a feather board secured
in the table slot with C-clamps(Figure
- Stock over
6" wide, use the feather board guard and a push block (Figure
You can remove
the entire edge of the stock or only part of it (Figure
9-13). It depends on the cutter you are using and the shape
you wish to produce. When only part of the edge is cut away, the
surfaces of the fence boards must be on the same plane (Figure
9-14). The workpiece moves across the cutter and receives the
same support from the outfeed board as it did from the infeed board.
Shaper cuts can remove part of or the entire edge of the workpiece.
Not: Depth of cut exaggerated for clarity.
When removing part of an edge, align the two fence boards.
When removing an entire edge, offset the outfeed board.
When the entire
edge of the workpiece is removed, fence alignment must be adjusted
to suit the depth of cut. You can do this by offsetting the outfeed
board (Figure 9-15).
Once the work has passed the cutter, the position of the outfeed
board must compen-sate for the change in the stock's width.
Use a feed that
is slow and steady. A slow feed allows the blades of the cutter
to work longer over a given area of the wood and this produces smoother
cuts, while allowing the cutter to work without choking. Of course,
this can be overdone. Judge feed speed so the cut progresses smoothly
without straining you or B the cutter. Try to work so you are cutting
with the grain of the wood. When you must cut against the grain,
use an even more conservative feed speed.
are attained by making two or three passes. Reposition the workpiece
and the cutter after the first pass to provide the additional cut
that completes the form. Operations like this are best handled by
first sketching the shape required on the edge of the stock, then
selecting cutters that will fit the contours of the form.
The drop leaf joint is sued to extend the size of a table
by means of hinged outer leaves.
This popular joint (Figure
9-16), is used to extend the size of a table by means of leaves
that are hinged to a fixed center section. The drop leaf joint,
or "rule joint" as it is sometimes called, is preferred over a simple
butt joint because of its neater, more professional appearance.
With the special
set of cutters, you can shape the edges of both the table and the
leaf so they will match perfectly. The table edge is formed as shown
in Figure 9-17.
The shoulder doesn't have to be as wide as it is on the cutter;
this will be dictated by the thickness of the tabletop and controlled
by the height of the cutter in relation to the workpiece when making
the pass. The full radius, however, should be formed since it will
have an impact on the appearance of the joint when the leaf is raised.
Figure 9-18 shows
a leaf edge be-ing shaped.
One cutter of the drop leaf set is used to form the table's
edge. It isn't necessary to form the shoulder to the cutter's
The second cutter is used to form the edge on the drop leaf.
This joint is frequently used when joining boards edge-to-edge.
The mating forms can be shaped by working with the set of cutters,
one to form the tongue, the other the groove, but it's also possible
to do both parts of the joint by working with a single blank cutter;
it depends on the thickness of the stock. For example, if the stock
is 3/4" thick and you have a 1/4" blank cutter, the work can be
done as follows:
Using a 1/4" blank cutter to form a groove exactly centered
in the edge of the stock.
Set the height
of the cutter to form a groove exactly centered in the edge of the
stock. Organize the shaper fence so the groove will be as deep as
the cutter is wide; then make two passes, the second one after the
workpiece has been turned end-for-end (Figure
The same cutter is used to form the tongue. The shape is the
result of opposing rabbet cuts made on the same edge.
The tongue is
formed as shown in Figure
9-20. Once the cutter height has been adjusted, it's just a
matter of forming opposing rabbets on each edge of the work-piece.
Make the first cut. Do not make a change in depth of cut. Then turn
the workpiece over and make the second cut. Be sure the tongue that
results will be a nice sliding fit in the groove.
Examples of stopped shaper cuts.
9-21 shows examples of stopped cuts made by using stop blocks.
Stop blocks, spaced to suit the cut length, are clamped to the shaper
fence as shown in Figure
9-22. Brace the end of the workpiece against the infeed stop
block and then swing it slowly into the cutter until its edge is
snug against the fence. Make the pass until the workpiece butts
against the out-feed stop block. Turn off the machine and let it
come to a complete stop. Carefully pull the trailing end away from
The length of the cut is controlled by stop blocks clamped
to the shaper fence.
You can do this
kind of work on pieces that are too long for the standard shaper
fence by making special long fence boards like the standard fence
Warning: Trying to form slim moldings by working on narrow pieces
of wood is a dangerous practice. To make slim moldings, shape the
edge of a large workpiece and then, working with either a hollow-ground
or carbide-tipped saw blade, cut off as much as you need. This
technique is also valuable because it enables you to form moldings
you would otherwise have to buy (for example, half-rounds); and
you can form the moldings in whatever kinds of wood you choose,
an option not available through commercial supply houses.
The nosing cutter of a flute and nosing set of cutters is
used here to round off the edge of a workpiece.
9-23 shows the start of such an operation using the nosing cutter
that is part of the flute and nosing set. After the edge is shaped,
the half-round is removed by sawing (Figure
When the edge of the workpiece is sawed off, you have perfect
Unless the workpiece is wide enough to provide sufficient
bearing surface against the fence boards, make all cross-grain
cuts with the miter gauge and safety grip.
Cross-grain cuts are seldom as smooth as those made with the grain.
To get the best results, use a very conservative feed rate and keep
the workpiece moving steadily. If the cuts are deep, make more than
one pass, adjusting the cutter after each pass until the shape is
fully formed. Warning: If the workpiece is not wide enough to
have sufficient bearing against the boards, use the miter gauge
and safety grip to secure the workpiece while making the pass (Figure
Make the cross-grain cuts first when shaping all four edges
of a workpiece.
If you are shaping
a square corner, always make the cross-grain cut first. The second
cut, made with the grain, will remove the slight blemish that is
inevitable at the end of cross-grain cuts. When you must shape all
four edges of a workpiece, do the cross-grain cuts first, then the
final cuts with the grain (Figure
Collars control the depth of cut. Always be sure there is
enough bearing surface between the workpiece and the collars.
are circular or have curved edges are done by pin shaping. This
is a special procedure made possible by mounting collars on the
arbor and using the shaper insert equipped with pins.
the pins and the table provide the bearing surfaces for the workpiece.
The cutter may be over the workpiece or under it. You can use more
than one collar of the same diameter to guide against thick stock.
Warning: The important factor is the contact area between the
workplece and collars (Figure
9-27). A small amount of contact area (less than half the collar
thickness) is not adequate; always organize for maximum collar contact
so the work will have good support.
Since the collars
turn with the cutters, they can score or burn the Work unless they
are kept smooth and free of gum, dirt, or dust. When you bear against
them, use only as much pressure as you need to maintain the contact.
will function whether they are over or under the work-piece. The
cut is easier to see and, some operators feel, is easier to control
when the cutter is on top. Warning: If the workpiece is tilted
up at any time during the pass, the cutter will dig into it.
Positioning the cutter under the workpiece is the safest way to
operate. Also, slight accidental lifting of the work during the
pass will do no harm.
The workpiece is first braced against the left pin and slowly
advanced to contact the cutter.
The major factor to consider when pin shaping is the initial contact
of the workpiece with the cutter. Warning: The workpiece, if
moved directly into the cutter without support, will be kicked back.
This is where the pins come into play. Start the pass by bracing
the workpiece against the pin at the left of the cutter. With the
workpiece firmly against the pin, slowly advance it to contact the
cutter until it is solidly against the collars. Once the cut is
well started, you can swing free of the left-hand pin and allow
the workpiece to bear only against the collars (Figure
9-28). Toward the end of the cut, you can allow the workpiece
to be supported by the right-hand pin.
The pass can be made with the workpiece against the collar.
Move the workpiece slowly in a clockwise direction.
Start shaping the edge of a circular workpiece by bracing it solidly
against the left starter pin and then advancing it slowly to engage
the cutter. After the workpiece bears firmly against the collar,
you can choose to maintain the pin contact as you turn the workpiece
clockwise (Figure 9-29)
or swing it clear so only the work-to-collar contact is maintained.
You can continue in this manner to complete the pass or, at the
end of the cut, allow the right-hand pin to support the workpiece.
The left-hnad pin comes into play when shaping irregular edges.
Be very careful when shaping small radii and sharp corners.
curved edges, such as those on fancy picture frames, wall plaques,
free-form tabletops, and so on, are shaped much like circular pieces
except that you should judge when to accept support from the left-hand
pin and when to allow the workpiece to bear only agianst the collar
Always start by bracing the workpiece against the pin. Work slowly
and carefully, especially when you must turn a sharp corner. Warning:
Keep your hands on the outside edges of the workpiece so they will
be away from the danger zone.
You can shape slim, curved moldings by working on the edge
of stock large enough to be safely handled.
To safely work on slim, curved moldings, you must follow the principle
that was described for slim moldings: shape the edge of a workpiece
that is large enough to be safely handled (Figure
9-31). Obey the rules that apply to pin and collar support for
the workpiece. After the shaping is finished, use a scroll saw or
bandsaw to remove as much of the edge as you need (Figure
Use a scroll saw or bandsaw to cut off the part you need after
the curved edge has been shaped.
Cut out and contour all inside edges first. The workpiece
is fed in a counterclockwise direction. Be especially careful
with hand placement. After completing the inside contour,
cut the outside contour and shape it.
Shaping a rabbet on the inside perimeter of a circular picture frame
to accommodate the glass is a typical example of inside edge shaping
The workpiece is placed in position before the cutter is extended
for depth of cut. The workpiece is braced against the right-hand
pin and then swung into contact with the cutter until it bears solidly
against the collar. It is then rotated counter-clockwise so the
pass is made against the direction of rotation of the cutter (Figure
You can shape inside edges as shown.
This kind of
work doesn't have to be limited to forming rabbets for glass in
circular frames. By working the same way, you can add decorative
internal edges on circular workpieces.
Here are examples of special fistures you can make when you
have many similar workpieces to produce. Fixtures mus be designed
to suit the work you are doing. The position of the fixture
determines how far the cutter penetrates the workpiece. The
fixture control area mus match the curve in the workpiece.
Be sure the contact areas are sanded smooth.
For production runs on specially shaped pieces, it is good practice
to create setups that provide accuracy while allowing you to work
safely. The ideas that are shown in Figure
9-35 are diagrammed just to demonstrate how fixtures can be
may be cut to shape on a scroll saw or bandsaw, sanded, and then
clamped to the worktable to serve as guides when feeding the work.
Quite often it is possible to use the scrap material from a cut
piece as the guide. For example, the scrap piece from a circular
cutout might make a good guide for shaping the edge of a circular
workpiece. This idea, of course, calls for very careful initial