Grizzly G2891 User manual

WOOD LATHE COPY ATTACHMENT
MODEL G2891
INSTRUCTION MANUAL
COPYRIGHT © 1993 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
REVISED APRIL, 1999. PRINTED IN U.S.A.

G2891 Lathe Copy Attachment -1-
Table Of Contents PAGE
1. SAFETY
SAFETY RULES FOR POWER TOOLS ................................................................2-3
ADDITIONAL SAFETY INSTRUCTIONS FOR LATHES ..........................................4
2. INTRODUCTION
COMMENTARY ........................................................................................................5
UNPACKING..............................................................................................................6
PARTS INVENTORY ................................................................................................6
SITE CONSIDERATIONS ........................................................................................7
3. ASSEMBLY
OVERVIEW................................................................................................................8
MOUNTING ..............................................................................................................9
ROUGH ALIGNMENT ............................................................................................10
FINAL ALIGNMENT ................................................................................................11
4. ADJUSTMENTS
CABLE TENSION ....................................................................................................12
GIB ADJUSTMENT ................................................................................................12
CUTTING TOOL ......................................................................................................13
COPY STYLUS........................................................................................................13
5. OPERATIONS
OVERVIEW..............................................................................................................14
IMPORTANT POINTS ............................................................................................14
BASIC OPERATION ..........................................................................................15-16
6. MAINTENANCE
LUBRICATION ........................................................................................................17
CUTTING TOOL ......................................................................................................17
7. CLOSURE ....................................................................................................................18
MACHINE DATA......................................................................................................................19
PARTS DIAGRAM ..................................................................................................................20
PARTS LIST ............................................................................................................................21
WARRANTY AND RETURNS..................................................................................................22

-2- G2891 Lathe Copy Attachment
Safety Instructions For Power Tools
SECTION 1: SAFETY
5. KEEP CHILDREN AND VISITORS
AWAY. All children and visitors should be
kept a safe distance from work area.
6. MAKE WORK SHOP CHILD PROOF with
padlocks, master switches, or by removing
starter keys.
7. DON’T FORCE TOOL. It will do the job
better and safer at the rate for which it was
designed.
8. USE RIGHT TOOL. Don’t force tool or
attachment to do a job for which it was not
designed.
1. KEEP GUARDS IN PLACE and in working
order.
2. REMOVE ADJUSTING KEYS AND
WRENCHES. Form habit of checking to
see that keys and adjusting wrenches are
removed from tool before turning on.
3. KEEP WORK AREA CLEAN. Cluttered
areas and benches invite accidents.
4. DON’T USE IN DANGEROUS ENVIRON-
MENT. Don’t use power tools in damp or
wet locations, or where any flammable or
noxious fumes may exist. Keep work area
well lighted.
For Your Own Safety Read Instruction
Manual Before Operating This Equipment
Indicates an imminently hazardous situation which, if not
avoided, WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, MAY result in minor or moderate injury. It may also
be used to alert against unsafe practices.
This symbol is used to alert the user to useful information
about proper operation of the equipment.
The purpose of safety symbols is to attract your attention to possible hazardous conditions.
This manual uses a series of symbols and signal words which are intended to convey the level
of importance of the safety messages. The progression of symbols is described below.
Remember that safety messages by themselves do not eliminate danger and are not a substi-
tute for proper accident prevention measures.
NOTICE

G2891 Lathe Copy Attachment -3-
9. USE PROPER EXTENSION CORD. Make
sure your extension cord is in good condi-
tion. Conductor size should be in accor-
dance with the chart below. The amperage
rating should be listed on the motor or tool
nameplate. An undersized cord will cause a
drop in line voltage resulting in loss of
power and overheating. Your extension
cord must also contain a ground wire and
plug pin. Always repair or replace exten-
sion cords if they become damaged.
Minimum Gauge for Extension Cords
10. WEAR PROPER APPAREL. Do not wear
loose clothing, gloves, neckties, rings,
bracelets, or other jewelry which may get
caught in moving parts. Non-slip footwear
is recommended. Wear protective hair cov-
ering to contain long hair.
11. ALWAYS USE SAFETY GLASSES. Also
use face or dust mask if cutting operation is
dusty. Everyday eyeglasses only have
impact resistant lenses, they are NOT safe-
ty glasses.
12. SECURE WORK. Use clamps or a vise to
hold work when practical. It’s safer than
using your hand and frees both hands to
operate tool.
LENGTH
AMP RATING 25ft 50ft 100ft
0-6 18 16 16
7-10 18 16 14
11-12 16 16 14
13-16 14 12 12
17-20 12 12 10
21-30 10 10 No
Safety Instructions For Power Tools
13. DON’T OVERREACH. Keep proper foot-
ing and balance at all times.
14. MAINTAIN TOOLS WITH CARE. Keep
tools sharp and clean for best and safest
performance. Follow instructions for lubri-
cating and changing accessories.
15. DISCONNECT TOOLS before servicing
and changing accessories, such as blades,
bits, cutters, and the like.
16. REDUCE THE RISK OF UNINTENTION-
AL STARTING. Make sure switch is in off
position before plugging in.
17. USE RECOMMENDED ACCESSORIES.
Consult the owner’s manual for recom-
mended accessories. The use of improper
accessories may cause risk of injury.
18. CHECK DAMAGED PARTS. Before fur-
ther use of the tool, a guard or other part
that is damaged should be carefully
checked to determine that it will operate
properly and perform its intended function.
Check for alignment of moving parts, bind-
ing of moving parts, breakage of parts,
mounting, and any other conditions that
may affect its operation. A guard or other
part that is damaged should be properly
repaired or replaced.
19. NEVER LEAVE TOOL RUNNING UNAT-
TENDED. TURN POWER OFF. Don’t
leave tool until it comes to a complete stop.

-4- G2891 Lathe Copy Attachment
Additional Safety Instructions For The G2891
No list of safety guidelines can be complete.
Every shop environment is different. Always
consider safety first, as it applies to your
individual working conditions. Failure to do
so could result in serious personal injury,
damage to equipment or poor work results.
This equipment has the potential to propel
debris into the air which can cause eye
injury. Always wear safety glasses or gog-
gles when operating equipment. Everyday
glasses or reading glasses only have
impact resistant lenses, they are not safety
glasses. Be sure your safety glasses meet
American National Standards Institute
(ANSI) standards.
Like all power tools, there is danger associ-
ated with the Model G2891 Lathe Copy
Attachment. Accidents are frequently
caused by lack of familiarity or failure to
pay attention to the tool or your work. Use
this tool with respect and caution to lessen
the possibility of operator injury. If normal
safety precautions are overlooked or
ignored serious personal injury may occur.
7. Before any copying operation, ensure
that the headstock and tailstock of your
lathe are centered on the same axis.
8. While working, position yourself so you
are within easy reach of all lathe and
Copy Attachment controls.
9. Keep base lubricated to ensure smooth
carriage movement during copying. DO
NOT lubricate the cable, it is friction
operated.
10. Do not make any adjustments to the
lathe or copy attachment while the lathe
is operating. If adjustments are neces-
sary, turn the lathe off, unplug the power
cord and wait for the moving parts to
stop.
11. Habits - good and bad - are hard to
break. Develop good habits and safety
will become second-nature.
1. Before turning your lathe on, ensure
that the cutting tool is well away from
the turning square. Ensure that the turn-
ing square will rotate freely.
2. Make sure the workpiece and the tem-
plate or master spindle are securely
mounted.
3. Always start the lathe at its slowest
speed.
4. Maintain minimal play in the guide cable
and carriage.
5. To prevent excessive vibration, don’t
force the cutting tool or take too big a
cut in one pass. Recommended maxi-
mum cut is 1⁄16"
6. Make sure cable path is unobstructed at
all times.

G2891 Lathe Copy Attachment -5-
SECTION 2: INTRODUCTION
Grizzly Industrial, Inc. is proud to offer the Model
G2891 Wood Lathe Copy Attachment. The
G2891 is part of Grizzly’s growing family of fine
woodworking and metalworking machinery.
When used according to the guidelines stated in
this manual, you can expect years of trouble-free,
enjoyable operation.
The Model G2891 is a wood lathe duplicator
capable of mass-producing many shapes of the
same design. The G2891 comes complete with
mounting hardware and cutting tool.
We are also pleased to provide this manual with
the Model G2891. It was written to guide you
through assembly, review safety considerations,
and cover general operating procedures. It repre-
sents our effort to produce the best documenta-
tion possible. If you have any comments regard-
ing this manual, please write to us at the address
below:
Grizzly Industrial, Inc.
C/O Technical Documentation
P.O. Box 2069
Bellingham, WA 98227-2069
Most importantly, we stand behind our
machines. If you have any service questions or
parts requests, please call or write us at the
location listed below.
Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Web Site: http://www.grizzly.com
The specifications, drawings, and photographs
illustrated in this manual represent the Model
G2891 as supplied when the manual was pre-
pared. However, owing to Grizzly’s policy of con-
tinuous improvement, changes may be made at
any time with no obligation on the part of Grizzly.
Whenever possible, though, we send manual
updates to all owners of a particular tool or
machine. Should you receive one, we urge you to
insert the new information with the old and keep
it for reference.
To operate this, or any power tool, safely
and efficiently, it is essential to become as
familiar with its characteristics as possible.
The time you invest before you begin to use
your Model G2891 will be time well spent.
DO NOT operate this machine until you are
completely familiar with the contents of this
manual. Make sure you read and under-
stand all of the safety procedures. If you do
not understand something, DO NOT oper-
ate the machine.
Commentary

-6- G2891 Lathe Copy Attachment
Unpacking
This Wood Lathe Copy Attachment is shipped
from the manufacturer in a carefully packed car-
ton. If you discover the machine is damaged after
you’ve signed for delivery, and the truck and dri-
ver are gone, you will need to file a freight claim
with the carrier. Save the containers and all pack-
ing materials for possible inspection by the carri-
er or its agent. Without the packing materials, fil-
ing a freight claim can be difficult. If you need
assistance determining whether you need to file a
freight claim, or with the procedure to file one,
please contact our Customer Service.
Parts Inventory
After all the parts have been removed from the
carton, you should have:
• Main Attachment Body
• Large Handwheel
• Hardware Box
5⁄8"-11 x 21⁄2" Socket Head Cap Screw 2
Threaded, Square Mounting Plate 2
Bed Brackets 2
Handwheel Handle 1
Cutting Tool 1
Unthreaded, Rectangular Mounting Plate 2
Allen®Wrench 4mm 1
Allen®Wrench 5mm 1
Allen®Wrench 14mm 1
M8-1.25 x 60mm Hex Bolt & Clamp Plate 2
M8-1.25 Hex Nut 2
3⁄8" Flat Washer 2
3⁄8" Lock Washer 2
In the event that any non-proprietary parts are
missing (e.g. a nut or a washer), we would be
glad to replace them, or, for the sake of expedi-
ency, replacements can be obtained at your local
hardware store.
When you are completely satisfied with the con-
dition of your shipment, you should inventory its
parts.
NOTICE
A full parts list and breakdown can be
found toward the end of this manual. For
easier assembly, or to identify missing
parts, please refer to the detailed illustra-
tions at the end of the manual.

G2891 Lathe Copy Attachment -7-
Site Considerations Notes
FLOOR LOAD
Your G2891, when mounted to your wood lathe,
represents a large weight load in a small foot-
print. Be sure that the floor in your work area is
adequately reinforced to support the weight of the
lathe and copy attachment.
WORKING CLEARANCES
Working clearances can be thought of as the dis-
tances between machines and obstacles that
allow safe operation of every machine without
limitation. Ensure that your working area offers
plenty of room for free movement and a substan-
tial amount of distance between you and others
that may be working in your shop space.
LIGHTING AND OUTLETS
Lighting should be bright enough to eliminate
shadows and prevent eye strain. Electrical cir-
cuits should be dedicated or large enough to han-
dle combined motor amp loads of the lathe and
other machinery connected to that circuit. Outlets
should be located near each machine so power
or extension cords are not obstructing high-traffic
areas. Be sure to observe local electrical codes
for proper installation of new lighting, outlets, or
circuits.
Make your shop “child safe”. Ensure that
your workplace is inaccessible to young-
sters by closing and locking all entrances
when you are away. Never allow visitors in
your shop when assembling, adjusting or
operating equipment.

-8-
Some metal parts may have sharp edges
(called “flashing”) on them after they are
formed. Please examine the edges of all
parts before handling them. Failure to do so
could result in skin laceration.
SECTION 3: ASSEMBLY
Overview
Most of your Copy Attachment has been assem-
bled at the factory. However, you will need to
attach the handle to the carriage handwheel,
mount the longitudinal-feed handwheel and cut-
ting tool and mount the main assembly to your
lathe.
NOTICE
All assembly and adjustment instructions
assume that your lathe is axially aligned,
i.e., the headstock and tailstock are cen-
tered on the same axis. Consult your lathe
owner’s manual for proper procedure.
1.1.
4.
5.
6.
7. 8.
9.
10. 11. 12. 13.
14.
2.
3.
1. Copy Carriage Bed
2. Carriage Travel Cable
3. Cutting Tool Carriage
4. Cutting Tool Arbor
5. Mounting Brackets (2)
6. Carriage Stop
7. Longitudinal Handwheel
8. Master Spindle Support
9. Crossfeed Handwheel
10. Stylus Height Adjuster
11. Stylus
12. Quill Gap Adjuster
13. Template Support (2)
14. Spindle Support Adjuster
The illustration below indicates the features and
controls included with the Model G2891.
Assembly, adjustments, operation and mainte-
nance procedures will all be more successful
after you develop an understanding of the copy
attachment’s construction and functions.
G2891 Lathe Copy Attachment

G2891 Lathe Copy Attachment -9-
Mounting
The Model G2891 mounts easily on Grizzly Lathe
Models G1067Z and G1495. It will also mount on
most other lathes having a bed size of at least
40''. Two mounting brackets attach the bed of the
Model G2891 securely to the bed of the lathe.
The mounting process is as follows:
1. Mount the two bed brackets perpendicular
to the lathe bed with the large cap screws
and the square threaded mounting plates
provided. The heads of the cap screws
should be on top of the brackets and the
mounting plates should be below the bed.
To provide a solid base for the Copy
Attachment base, the mounting brackets
should be centered on points measuring
20% of the distance across the bed from
the headstock and tailstock. See Figure 2.
On a lathe with a 40" bed, brackets will be
centered approximately 8" from the head-
stock and tailstock. Some minor degree of
variation may be necessary to eliminate
any interference between the Copy
Attachment and the normal operation of the
lathe.
The front of the brackets should cantilever
over the front of the lathe bed by about 6".
Just finger-tighten the cap screws for now.
Figure 3. Sliding attachment onto bolts.
2. Slide the two hex head bolts with clamping
plates attached into the channel located
along the bottom of the Copy Attachment
main body. See Figure 3. Place the Copy
Attachment onto the bed brackets installed
in Step 1, dropping the hex bolts through
the bed bracket slots at the front of the
lathe. Center the attachment body with the
lathe bed and slip the packing block, flat
washers, spring washers and nuts provided
over the hex bolts and just finger-tighten.
Make certain the Copy Attachment does
not block access to any of the lathe con-
trols. Some lateral adjustment can be done
to assure clearance if necessary.
20%
20% 60%
Figure 2. Attachment locations for left and right bed attachment brackets.

-10- G2891 Lathe Copy Attachment
4. Tighten the large cap screws securing the
mounting brackets to the lathe bed with the
large Allen®wrench provided. Then tighten
the hex nuts securing the Copy Attachment
Bed to the mounting brackets.
5. Once the brackets and bed are securely
attached, remove the gauge boards.
6. Install the longitudinal-feed handwheel.
This is the larger of the two handwheels. It
mounts on the shaft at the left hand end of
the Copy Attachment Bed. Secure the
wheel with the setscrew included.
7. Attach the crossfeed handwheel handle to
the smaller wheel on the the sliding car-
riage.
8. Install the cutting tool into the arbor and
tighten the collar setscrew. See Figure 5.
Once the Copy Attachment Bed is attached to
the mounting brackets, the following procedures
will allow you to begin the very important process
of aligning the parallelism between the centers of
the lathe and those of the centers which will hold
your template or original profile.
1. To roughly align the Copy Attachment with
the lathe headstock/tailstock axis two
gauge boards will be needed. The gauge
board should be approximately 1- 11⁄8''
thick, 6 - 8'' wide and 2 - 3'' long. Clamp
these gauge boards onto the lathe bed,
one under the headstock, the other under
the tailstock.
2. Place a machinist’s square on top of the
wood and measure 3'' toward the Copy
Attachment bed. See Figure 4. Place a
precise mark across the width of the wood.
Repeat the process with another piece of
wood at the headstock.
Rough Alignment
3"
Copy
Attachment
Bed
Figure 4. Use of gauge boards for alignment.
3. Once both gauges are marked, slide the
Copy Attachment bed over the board until
the leading edge is even with the marks on
both the left and right sides.
Use caution when handling the Copy
Attachment’s cutting tool. It’s sharp edges
could cause skin lacerations if handled
improperly.
Figure 5. Securing cutting tool.

G2891 Lathe Copy Attachment -11-
Final alignment of the lathe axis and the copier
axis must be precise to ensure that they are both
parallel. Before executing the following steps,
mount a turning square between the centers of
your lathe.
The turning square should be as long as the max-
imum center-to-center distance of your lathe to
ensure the greatest degree of accuracy. It is crit-
ical that the turning blank is perfectly centered
and as near-perfectly straight as possible.
1. Move the carriage to one end of the Copy
Attachment and crank the cross-feed hand-
wheel until the cutting tool nearly touches
the side of the blank. See Figure 6.
Final Alignment
NOTICE
If the carriage is difficult or impossible to
move along the bed, see Gib Adjustment in
next section.
Figure 6. Aligning lathe to copy attachment.
very carefully adjust the bed until the cutter
is equal distant from the turning square at
both ends of its longitudinal movement.
4. Continue to test the cutter against the turn-
ing square until it is evenly spaced in rela-
tion to the turning square along its entire
length.
5. Once adjustments are complete, ensure
that all mounting bolts are securely tight-
ened.
Figure 7. Using precision spacer.
Avoid wearing loose-fitting clothing, jewel-
ry, or other personal items that could be
caught in moving parts of the machinery
while adjusting or operating this machine.
Serious personal injury could result if this
warning is ignored.
2. Without changing the position of the turning
blank, slowly turn the longitudinal feed
handwheel to move the carriage toward the
opposite end of the lathe. Use a feeler
gauge or another precision spacer when
starting out to ensure consistent distance
between the cutter and the turning square.
See Figure 7.
3. If the cutter does not maintain a consistent
distance from the turning square at both
ends of the cutter’s longitudinal movement,
or along it’s length, you may have to loosen
the bed from its mounting brackets and
very

-12- G2891 Lathe Copy Attachment
Cable Tension
SECTION 4: ADJUSTMENTS
The movement of the carriage assembly along
the body of the Copy Attachment is controlled by
the movement of the Longitudinal-Feed
Handwheel. This Handwheel is connected to the
carriage via a cable. This cable should be taut to
ensure responsive movement of the carriage.
The cable can be tightened by loosening the bolt
at the control rod. See Figure 8. The cable
should then be pulled snugly, but not so tight that
stress is placed on the cable. Once snug, re-tight-
en the bolt to secure the cable.
Gib Adjustment
The carriage slides along the Copy Attachment
bed on brass strips called gibs. These gibs are
the means by which you adjust the amount of
friction or play between the carriage and the bed.
Figure 8. Adjusting carriage cable tension.
Figure 9. Adjusting the gib tightness.
The goal of gib adjustment is to provide as little
play as possible between the carriage and the
bed while still allowing free movement of the car-
riage.
There are eight adjustment locations: 2 on the
front of the carriage, 2 on the back and 4 under-
neath.
To adjust the gibs:
1. Loosen the lock nut(s) and and loosen or
tighten the setscrews with the 3mm Allen®
wrench.
2. Slide the carriage back and forth to test for
binding and re-adjust until the carriage
travels smoothly, without binding or excess
wobble.
3. When adjustments are complete, tighten
the lock nuts while maintaining the
setscrew position with the Allen®wrench.
See Figure 9. Re-test after tightening.

G2891 Lathe Copy Attachment -13-
Cutting Tool
The cutting tool can be positioned closer or far-
ther away from the workpiece by loosening the
setscrew at the top of the cutting tool collar. Use
an 8mm Allen® wrench to make collar adjust-
ments. To install or replace the cutting tool:
1. Loosen the setscrew on the cutting tool col-
lar.
2. Insert the cutting tool with the triangular
cutting edge up. See Figure 10.
3. Tighten the setscrew.
Figure 10. Cutting tool and setscrew.
Copy Stylus
To ensure the greatest level of precision while
copying from a template or a master profile, it is
essential that the Copy Stylus is properly posi-
tioned at the underside of the travelling carriage.
When adjusting the stylus, keep in mind that its
follower edge should be centered on the template
or master profile, so the narrowest point fits
securely within the profile. To adjust the stylus:
1. Center your master profile on the copy cen-
ters, or attach your profile template to the
attachment brackets included on the front
of the Copy Attachment body. Insert the
stylus so the rounded edge of the follower
contacts the master. See Figure 11.
2. Be sure that your template or master profile
is perfectly parallel to the Copy Attachment
bed by repeating the procedures used to
check alignment between the lathe centers
and the Copy Attachment. This time, move
the stylus from one end of the template or
master profile to the other by turning the
longitudinal handwheel. The cross-slide
handwheel will allow you to adjust the loca-
tion of the stylus, so you can find points on
either end of the profile which will allow you
to ensure proper alignment. Adjust the sty-
lus height until the follower edge is cen-
tered on the template or profile. Tighten the
setscrew to secure the stylus.
Figure 11. Stylus follower edge.

-14- G2891 Lathe Copy Attachment
SECTION 5: Operations
Overview
This Copy Attachment will produce any number
of duplicate spindles from one master profile or
template. The advantages provided by this
accessory for your wood lathe are readily appar-
ent, in terms of consistency and labor savings.
While the Copy Attachment provides a substan-
tial aid in recreating spindle profiles, keep in mind
that it is designed primarily for rough spindle
shaping. Its capacity for detail is limited by the
cutter and stylus. Final detailed turning will be
best accommodated with the use of hand-guided,
precision turning chisels.
To minimize the need for extensive hand work,
we recommend you create profiles with graceful
tapers and beads whenever possible.
Important Points
Because small-diameter master spindles have
the potential to bend or bow slightly when the sty-
lus makes contact, we recommend using a tem-
plate made from 1/4" to 3/8" plywood or some other
stable material. The master spindle profile can be
transferred to the template and carefully cut out.
The template can then be attached to the mount-
ing brackets located on the front side of the Copy
Attachment body. See “Stylus Adjustment” in the
Adjustment Section for details on proper template
alignment.
The following are some other important points to
consider when using your Copy Attachment:
•To reduce whip and vibration of relatively
narrow copy spindles, we recommend oper-
ating the longitudinal handwheel with your
left hand and backing up the spinning work-
piece with your right. DO NOT attempt to
grip the workpiece too tightly while it is turn-
ing.
•If the cut you are producing is too rough, try
increasing the rotation speed of your lathe
(not to exceed the maximum recommended
speed for the size of material you are turn-
ing) and take a lighter cut. See your lathe’s
instruction manual for recommended
speeds.
•As with any other surfacing operation, we
recommend taking multiple passes, rather
than trying to remove too much wood all at
once. This is much safer and will also result
in improved cutting results.
•When making copies, always move the sty-
lus so it follows the template or master pro-
file “downhill”. Trying to move the stylus
“uphill” along the template will cause the sty-
lus and cutter to dig into the template and
workpiece. See Figure 12 for recommended
direction of cuts.
•To avoid unnecessary waste of expensive
premium materials, we strongly recommend
you turn a test piece before attempting dupli-
cation on your finish material. Make adjust-
ments as required.
•You can save time during duplication by
removing the corners from all of the spindles
you plan on creating before activating the
Copy Attachment. You will need to make the
cuts with a lathe chisel on your tool rest,
prior to installing the Copy Attachment.

G2891 Lathe Copy Attachment -15-
Basic Operation
Master Spindle or Template
Stylus
Move from high points towards
areas with greater depth of cut
Figure 12. Recommended direction of stylus travel.
To make a copy of an existing spindle or tem-
plate:
1. To make identical copies from a master
spindle it is necessary to first make certain
the cutting tool and the follower stylus are
aligned with their respective centerlines.
See Figure 13. This can be done most eas-
ily by mounting turning squares with identi-
cal dimensions on the lathe centers and on
the Copy Attachment centers. Move the fol-
lower stylus so it just touches the square.
Adjust the cutting tool in or out of the hold-
er so it also just touches the square.
Remove the turning squares.
2. Mount the workpiece between the lathe
centers.
3. Move the carriage with the longitudinal
handwheel until the tip of the cutter is pre-
cisely located at the point on the workpiece
where you want the turning action to begin.
See Figure 12.
Lathe Centerline
Copy Attachment
Centerline
Cutting Tool
Follower Stylus
Figure 13. Stylus/Cutting Tool alignment.
4. If you are using a template, spread the tem-
plate-mounting brackets apart to accom-
modate the template. Note that you will
have to drill holes in your template to mount
it to the template mounting brackets.
Locate the position of the template on the
Copy Attachment main body so the profile
will line up with the desired location of the
profile on the workpiece. If you followed
Step 2, the stylus should line up at the start-
ing point of the template.
5. Adjust the crosswheel until the stylus
comes in contact with the template in its
desired position.
6. If duplicating an existing spindle, mount the
spindle between the master spindle carri-
ers. First position and lock the head center
so the existing spindle profile will line up
with the intended profile area on the copy.
Use a 13mm wrench to loosen and tighten-
ing the mounting fasteners. Slide the tail
center so it is just outside of the master
spindle, and lock in place. Hold the master
spindle in position and tighten the hand
knob located on the tail center.
Make sure that the workpiece is firmly seat-
ed between centers. If it becomes unseated
from the lathe at operating speed, the work-
piece will be propelled from the machine.
Serious personal injury will occur to anyone
in the path of the workpiece.

-16- G2891 Lathe Copy Attachment
7. Move the carriage stylus to the left hand
limit of the profiled area and adjust the left
hand stop until it is in contact with the car-
riage. See Figure 14. Tighten the stop with
a Phillips®head screwdriver.
8. Repeat the procedure for the right hand
stop.
Figure 14. Adjusting positive stops.
9. Once the template and the workpiece are
both securely in place, loosen the cutter in
its collar and adjust it until both the cutter
and the stylus are just touching the work-
piece evenly and the template evenly. It is
essential for accurate copying that the cut-
ter tip and the tip of the stylus always
remain at the same positions in relation to
the workpiece and the master profile. Slide
the carriage away from the workpiece, so
both the stylus and cutter are well away
from your work.
10. Ensure that everything is secure and turn
on the lathe at its slowest speed. Slowly
advance the cutting tool toward the left
edge of the workpiece. Once contact is
made, advance the cutting tool into the
copy spindle approximately 1/16". Turn the
longitudinal handwheel so the carriage
travels from stop to stop.
11. After each pass, extend the cutter another
1/16" (maximum) and repeat with another
pass. Repeat this process until the stylus
comes in contact with the template.
12. Watch the tool carefully as you make each
pass. If it tends to bite or gouge the work-
piece, back the cutter slightly and try
again. Be conservative when removing
stock.
13. After you’ve made several passes with the
cutting tool, turn the lathe off and inspect
the results. It should not be tapered. If it is,
the Copy Attachment is not properly
aligned to the axis of the wood lathe. Re-
align the attachment, according to the
instructions in the Assembly and
Adjustment Sections and re-try with a new
test cut.
14. If you are satisfied, continue to remove
material from the workpiece, using the
“downhill” cutting method shown earlier.
Remember, trying to cut “uphill” will likely
result in chipping and gouging. Don’t do it.
15. Continue removing stock until the work-
piece is complete. See Figure 15.
Figure 15. Shaping the copy spindle.
16. After completing the initial copy, continue
following these procedures until all the
spindles are completed.
17. When all spindles are complete, remove
the Copy Attachment and replace it with
the lathe’s tool post.
18. Use appropriate lathe chisels to sharpen
details and smooth the turned surfaces of
each copy. Sand smooth.

G2891 Lathe Copy Attachment -17-
SECTION 6: MAINTENANCE
After each copying session, wipe the lathe and
Copy Attachment with a clean cloth to remove
accumulated chips and sawdust.
1. Apply a light spray lubricant to the longitu-
dinal and crossfeed gears.
2. To prevent rust and corrosion, apply an
occasional coating of carnauba paste wax
to the bed and other non-painted surfaces.
3. Above all else, keep the entire Copy
Attachment, as well as the wood lathe,
clean and free of accumulated dirt and
grime that could impede free movement of
the carriage, cutter, stylus or other working
parts.
Never allow visitors into your shop while
assembling, operating, or maintaining tools
and machinery. Keep your shop child-safe
by locking up securely when not in use, and
by providing proper supervision when chil-
dren are present.
Lubrication Cutting Tool
After extended use, particularly with hardwoods
or woods with large amounts of oil or resins, the
cutter may become dull.
When you notice that the cutter seems to be
working abnormally hard while cutting, or if over-
heating or frequent gouging and chipping occur,
you will need to either sharpen or replace the cut-
ting tool. Loosen the collar setscrew and remove
the tool, and sharpen or replace as needed.
Cutting tools will become very hot when in
use. Use care when removing a cutting tool
which has just been used. It can still be
extremely hot and cause painful burns.
Wear gloves, or wait for the tool to cool
down before removing or adjusting.

-18- G2891 Lathe Copy Attachment
The following pages contain general machine
data, parts diagrams/lists, troubleshooting guide
and Warranty/Return information for your Model
G2891 Lathe Copy Attachment.
If you need parts or help in assembling your
machine, or if you need operational information,
we encourage you to call our Service
Department. Our trained service technicians will
be glad to help you.
If you have comments dealing specifically with
this manual, please write to our Bellingham,
Washington location using the address in Section
2 Introduction. The specifications, drawings, and
photographs illustrated in this manual represent
the Model G2891 as supplied when the manual
was prepared. However, due to Grizzly’s policy of
continuous improvement, changes may be made
at any time with no obligation on the part of
Grizzly. Whenever possible, though, we send
manual updates to all owners of a particular tool
or machine. Should you receive one, add the new
information to this manual and keep it for refer-
ence.
We have included some important safety mea-
sures that are essential to this machine’s opera-
tion. While most safety measures are generally
universal, Grizzly reminds you that each work-
shop is different and safety rules should be con-
sidered as they apply to your specific situation.
We recommend you keep a copy of our current
catalog for complete information regarding
Grizzly's warranty and return policy. If you need
additional technical information relating to this
machine, or if you need general assistance or
replacement parts, please contact the Service
Department listed in Section 2: Introduction.
Additional information sources are necessary to
realize the full potential of this machine. Trade
journals, woodworking magazines, and your local
library are good places to start.
SECTION 7: CLOSURE
The Model G2891 was specifically designed
for use with 40" Wood Lathes. DO NOT MOD-
IFY AND/OR USE THIS MACHINE FOR ANY
OTHER PURPOSE. Modifications or
improper use of this tool will void the war-
ranty. If you are confused about any aspect of
this machine, DO NOT use it until you have
answered all your questions. Serious person-
al injury may occur.
Operating this equipment has the potential
to propel debris into the air which can
cause eye injury. Always wear safety glass-
es or goggles when operating equipment.
Everyday glasses or reading glasses only
have impact resistant lenses, they are not
safety glasses. Be certain the safety glass-
es you wear meet the appropriate stan-
dards of the American National Standards
Institute (ANSI).
Like all power tools, there is danger associ-
ated with the Model G2891 Copy
Attachment. Accidents are frequently
caused by lack of familiarity or failure to
pay attention. Use this tool with respect and
caution to lessen the possibility of operator
injury. If normal safety precautions are
overlooked or ignored, serious personal
injury may occur.