Popular Woodworking 2002-12 № 131, страница 64

portions of the cutterhead can be safely positioned below the surface of the table. By far, the most important part of the setup is a starting pin. The pin is positioned close to the cutterhead and acts as a fulcrum to provide leverage to safely start the cut. Once the workpiece contacts the bearing, it can be pivoted away from the starting pin to complete the cut.

Whenever shaping curves freehand, it's crucial that you limit the cutting depth by using a large diameter bearing. Also, the work-

piece must be large enough to provide mass and safe positioning of your hands.

Shaping Curves with a Template

The second method of shaping curves uses a shop-made template to guide the work. This method is the only option when the entire edge of the curved workpiece must be shaped. The workpiece may be secured to the template with toggle clamps or screws or a combination of both. Be sure

to leave the workpiece oversize until after shaping to provide extra mass and room to fasten the work to the template.

When designing and constructing the template, be sure to keep several factors in mind. First, extend the template beyond the workpiece. This way the template will contact the shaper's guide bearing before the cutterhead will contact the stock. This method provides a smooth, safe entry to the cut. Second, make sure the template is large enough to safe

ly distance your hands from the cutterhead. Plastic push blocks fastened to the template work well as hand grips.

Finally, always take light cuts when shaping curves. Start each series of cuts with a large diameter guide bearing to limit the cutting depth. After each successive cut, switch to progressively smaller diameter bearings until the final profile depth is reached. PW

Using the right guard and keeping your hands away from the cutterhead will help avoid accidents.

SHAPING SAFELY

All woodworking machines have inherent safety risks - and the shaper is no exception. In fact, the shaper has a reputation as a somewhat dangerous machine. However, as a long-time woodworker with nearly 25 years of experience using the shaper, I can say that it's a safe, productive machine when set up and used properly. As with any machine, always read the owner's manual and manufacturer's safety guidelines, use guards and push-blocks, and exercise common sense. In addition, here are guidelines that I follow when using the shaper:

1. Avoid heavy cuts. Heavy cuts on a shaper are much more prone to kickback.A safer alternative is to shape the profile in several small passes or to remove excess stock first using your table saw.

2. Always feed the workpiece against the rotation of the cutterhead. If your shaper has a reversing switch, make certain of the rotation of the cutterhead before you begin.

3. Select the appropriate spindle speed. Large diameter cutterheads, such as those designed for panel-raising, have a higher rim speed than small diameter cutterheads and should be run at a lower rpm.

4. Keep the fence opening as small as possible. This safety precaution helps prevent the workpiece from dropping into the cutterhead.

5. Position the cutterhead so that it cuts from underneath the workpiece. Using this method, the workpiece acts as a barrier and any portion of the cutter not being used will be safely positioned below the shaper table's surface.

6. Avoid shaping short, thin or narrow stock. Instead, first shape an oversize piece of stock, and then size it to the dimensions needed after shaping.

7. Use spring holddowns and featherboards whenever possible.

These simple devices aid in keeping the stock against the table and fence, reducing vibration and helping to keep the workpiece flowing in the intended path.

8. Always keep hands a minimum of 6" from the cutterhead. Use pushblocks, jigs and pushsticks.

9. Always use a starting pin when shaping freehand. The starting pin works as a fulcrum to allow you to safely pivot curved work into the spinning cutterhead and against the guide bearing.

10. When shaping with a template, extend the template beyond the workpiece. This way, the template will contact the guide bearing before the workpiece contacts the cutterhead.

11. Disconnect the shaper from its power source before making any setups or adjustments.

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Popular Woodworking December 2002