Shopsmith Lathe Duplicator User manual

Lathe Duplicator
555209
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Introduction Safety
Your Shopsmith Lathe Duplicator
accessory provides a simple and ac-
curate way to produce duplicate spin-
dles and bowls, making possible a
new and precise method
of lathe turn-
ing. The
duplicator components are
designed
to mount on the Shopsmith
Mark V Models
500 and 510 as well
as on Mark
II and Mark VII systems.
NOTE
• Ifyou received your Mark V prior
to November 1985, you own a
Model 500.
• If you received your Mark V after
November 1985, you own either
a Model
500 or Model 510. Check
the vent plate, located around
the auxiliary spindle, for the
Model Number of your Mark V.
Rather than using conventional
lathe chisels, the Lathe Duplicator
features a tool rest assembly which
slides on a smooth table. You're in
complete control of the tool rest as-
sembly as you grasp its
two handles
and guide
its follower along a tem-
plate and
it..? carbide cutter into your
workpiece. The carbide
cutter has
an extremely tong cutting life without
sharpening.
A durable channel assembly provides
an adjustable mounting track for two
template support assemblies and a
guard assembly. With the template
centerline located directly over the
workpiece centerline, the tool rest as-
sembly is free
to be moved around the
table,
following the template and
producing an exact duplicate. The ad-
vantages of this configuration include
the
ability to turn bowls as well as
spindles and
to produce true under-
cuts . When duplicating spindles, use
either a flat template or
an existing
spindle. For bowl turning,
only a flat
template can be used. If you wish,
you can work
without a template to
develop skill.s in freehand turning.
As you operate the Lathe Duplicator,
you must be responsible for knowing
your own
limitations as well as those
of the duplicator . To avoid serious
injury,
constantly remind yourself to
use the accessory correctly together
with the proper safety equipment.
We wish you the best in all your
woodworking endeavors.
We know that
your Shopsmith Lathe Duplicator will
become
an indispensable accessory in
your workshop.
We know that you' re eager to get
started using your Lathe Duplicator,
but please take time to read this man-
ual before you begin. Then keep it
handy for future reference.
Table of Contents
Safety .................. . .... . .. 2
General Information
....... .. ..... 5
Assembly and Setup
... .......... 6
Alignment and Adjustment ... . ... . 11
Templates ...... ... ..... . .. . .... 13
Operations . ..... ... . . .. .... . . ... 15
Maintenance ........... ...... ... 26
Troubleshooting ............ .. . . . 27
Parts List .............. . . .... ... 28
Quick Reference Index ....... . .. . . 31
The Shopsmith Lathe Duplicator has
many built-in safety features. But the
effectiveness of these features
de-
pends on you. Power tool safety is no
more than good common sense.
To protect yourself from injury:
• READ, UNDERSTAND AND FOLLOW
ALL the
information in this Owners
Manual WHENEVER you operate, set
up, align, adjust, repair and maintain
the
lathe Duplicator.
• Also, READ, UNDERSTAND AND
FOllOW ALL the information in the
Owners Manual
for the Mark V on
which the Lathe Duplicator will be
mounted.
Throughout this manual, we
list
WARNINGS, CAUTIONS, and NOTES.
We advise that when you come to
one of these listings, please read and
understand it fully. Their meanings
are:
WARNING
A WARNING is given when failure
to follow the directions could reo
suit in injury, loss of limb, or life.
A CAUTION is given when failure
.to follow the directions cou~d r')·
suit in temporary or permanent
damage
to the equipment.
NOTE
A NOTE is used
to highlight an im-
portant procedure, practice or
condition.
Eye Protection
Always wear eye protection when you
use power tools. Use goggles, safety
glasses or a face shield to protect
your eyes.
• Goggles completely surround and
protect your eyes. Many goggles will
also
fit over regular glasses. Be
sure your goggles fit closely, but
comfortably.
2

WARNING Safety
• Safety glasses don't fog as easily as
goggles and can be worn all the
time. Regular glasses normally have
only impact resistant lenses. They
are not safety glasses.
• A face shield protects your entire
face, not
just your eyes. And you can
flip it up out
of the way when you
don't need it. A face shield can be
used with regular glasses.
Ear Protection
Prolonged exposure to high intensity
noise from high speed power tools
can damage your hearing.
• Hearing protectors screen out noise
levels that can damage ears. Wear
hearing protectors when you're ex-
posed
to high intensity power tool
noise for prolonged periods
of time.
Sawdust and Chips
Sawdust and chips can be fire hazards
and breathing sawdust can
be a health
hazard. Sawdust may cause you phys-
ical discomfort, especially if you have
emphysema, asthma, or
an allergic
reaction. The sawdust from some
woods can also be toxic.
• Wear a close-fitting
dust mask if a
significant amount of dust is re-
leased into the air. Clean or replace
the filters in the mask regularly.
• Open a window or use a fan
to venti-
late your shop.
Guarding for Turning
Most shop accidents happen to wood-
workers who believe they are too
experienced to use the guards and
safety devices. Although proper use
of
guards and safety devices usually
requires a small amount
of additional
setup, the security
that you and your
family obtain from them is well worth
the effort. Don't take shortcuts. It
doesn't pay.
• Keep the guard in place during
duplicator operations. Also use the
guard when doing conventional
lathe turning on the Mark
V.
Dress
Loose hair and clothing which could
be entangled in rotating workpieces
are very hazardous.
• Tuck long hair under a hat or tie it
up. Do not wear ties, gloves, loose
clothing or jewelry. Roll sleeves up
above your etbows.
General Safety Rules
for Power Tools
• Know your power tool. Read the
owners manual carefully. Learn
its
application and limitations as well as
the specific potential hazards pecul-
iar to the tool.
• Ground all tools (unless double
insulated). If tool is equipped with an
approved 3-conductor cord and a
3-prong grounding type plug to fit the
proper grounding type receptacle,
the green conductor in the cord is
the grounding wire. Never connect
the green wire to a live terminal.
• Wear proper eye and ear protec-
tion_ Also, wear a dust mask.
• Keep guards in place. Always
keep guards in working order and in
proper alignment and adjustment.
Most injuries
occur on unguarded
power tools.
• Remove adjusting keys and
wrenches. Form habit
of checking to
see
that keys and adjusting
wrenches are removed from tool be-
fore turning it on.
• Wear proper apparel. Do not wear
loose clothing, ties, gloves, or jew-
elry. Roll sleeves up above your el-
bows, wear nonslip footwear, and
tucUong hair under a hat.
• Do not operate power tools if you
are fatigued, taking medication, or
under the influence of alcohol or
drugs.
•
Avoid dangerous environments.
Don't use power tools in damp, wet
or explosive atmospheres.
• Keep work areas well lit, clean,
and free from clutter.
•
Do not force the tool. It will do the
job better and safer at the rate for
which it was designed.
• Use the right tool. Don't force a
tool or accessory
to do a job for
which it was not designed.
• Direction of feed. Feed the work-
piece into the
cutter against the ro-
tation of the cutter ONLY.
• Check damaged parts. A dam-
aged guard
or part should be prop-
erly repaired or replaced before
further use. If a strange noise or vi-
bration develops, immediately turn
off the power, unplug the machine
and correct the problem.
• Secure workpieces. Use clamps,
fixtures, and other devices
to hold
workpieces when practical. It's safer
than using your hands and it frees
your hands
to operate the tool.
• Do not overreach. Keep proper
footing and balance at all times.
• Turn off the tool and wait until it
comes to a complete stop before
re-
moving workpieces and scraps.
• Do not try to stop the tool by grab-
bing the workpiece or any part
of the
tool. Turn
off the tool and let it come
to a complete stop by itself.
• Do not leave tool running unat-
tended. Turn power off. Don't leave
tool until it comes to a complete
stop.
• Avoid unintentional starting.
Make sure the switch is in the "off"
position before plugging in or un-
plugging the tool.
• Disconnect tools. T'I'rn off and un-
plug tools before changing acces-
sories and setups, making ad-
justments, and performing mainte-
nance and repair.
• Do not stand or lean on the tool.
You could fall onto the tool or it could
tip over injuring you and/ordamaging
the tool.
• Maintain tools. Keep parts and
tools sharp, clean and maintained
according to the Owners Manual.
• Make workshop childproof. Use
padlocks, masterswitchesor remove
starter keys.
• Keep children away. All visitors
should stay a safe distance from
power tools, and wear eye and ear
protection.
• Use recommended accessories.
Consult the owners manual for rec-
ommended accessories.
3

r
WARNING
Safety
Safety Rules for the Shopsmith Lathe Duplicator
• Keep your hands, fingers and
other parts of your body 2" away
from the rotating workpiece
until it
is rounded. After it is rounded use
caution when you
get close to the
rotating workpiece.
Do not touch the
workpiece as
it turns.
• Keep the guard in place when·
ever you're performing turning oper·
ations. Position
it not more than 1/2"
from the workpiece.
•
When turning glued·up stock,
make sure glue joints are strong.
Glue the stock and leave it clamped
for at least
24 hours prior to turning.
• Wear proper apparel. Never wear
jewelry, gloves, ties, loose
clothing
or clothing with long sleeves. Keep
long hairtucked underahat. Jewelry,
gloves, ties,
clothing and hair could
become entangled in the workpiece.
• Do
not exceed recommended
speeds. Use the lowestspeed setting
when starting to turn a new
workpiece.
• When mounting
stock between
the centers, the spurs
of the drive
center and the cup of the tailstock
center must penetrate at least 1/16"
into the stock. Do not use a drive
center
or tailstock center if the point
is damaged. The stock could be
thrown from the lathe.
• Wax or soap the end of the stock
that mounts to the cup center. This
lubrication helps keep the center
from wearing
into the stock and
causing the stock to loosen on the
lathe. The ball bearing live center is
highly recommended
for use with the
Lathe Duplicator.
• When
mounting stock to a face·
plate, use
#12 x 1·1/4" long screws.
The screws must penetrate at least
1" into the stock. The surface of the
workpiece
that's against the face·
plate must be smooth and true.
• Cut faceplate
stock round and
spindle
stock that's more than 3"
square into an octagon. This reo
moves excess stock, minimizes im·
balance, reduces vibration and
makes turning large diameter stock
safer and easier.
• Check the balance
of the work·
piece. Prior
to mounting workpieces
more than 3" in diameter, check and
adjust the center of balance (dy·
namic center). Unbalanced work·
pieces could be thrown from the
lathe.
• Do
not turn on the power with the
cutter or any part of the tool rest as·
sembly against the workpiece. Turn
on the machine and
let it come up to
speed before starting the cut.
• Do
not stand in the path of rota·
tion of the workpiece when you first
turn on the machine. If the machine
is set on the wrong speed
or the
workpiece is unbalanced or improp·
erly mounted, the workpiece could
be thrown from the lathe.
• Feed the
cutter slowly into the
workpiece. Use both hands to hold
onto and control the tool rest
assembly.
• Periodically, turn
off the machine
and check
that the workpiece is held
securely between the centers or on
the faceplate.
• Do not lean across
or reach un·
derneath the lathe while it is running.
•
Do not try to stop the lathe by
grabbing the
stock or any part of the
machine. Turn
off the power and,let
the lathe come
to a complete stop
by itself.
•
Do not part the stock completely
or turn the spindle down to such a
small diameter
that it snaps on the
lathe. This can be extremely
dangerous.
• Do
not turn stock with splits,
loose knots, or
other defects that
could cause the stock to break,
splinter or come loose while turning.
Never turn second·hand lumber. If
you
hit a nail or screw, you could be
hit by pieces of metal.
•
Remove the Lathe Duplicator
from the Mark V before sanding or
finishing a workpiece on the lathe.
• Use
only recommended
Shopsmith parts and accessories on
your Lathe Duplicator. NEVER use
non·Shopsmith replacement parts or
accessories. They are not designed
like Shopsmith parts. Using no , n.:-
Shopsmith parts may create a r. .az.
ardous condition and will void-' jour
warranty.
•
Do not grind thecutters. The dust
created by grinding the carbide can
cause eye and skin irritation as well
as respiratory system and internal
organ damage. Replace worn cutters
with new.
• Do
not allow the cutter to come
in
contact with the parts of the Lathe
Duplicator or Mark V. The cutter will
cause damage to the parts and you
could be hit by pieces of metal.
4

General
Information
Getting to Know Your
Shopsmith Lathe
Duplicator
Your Shopsmith Lathe Duplicator is a
versatile accessory. Become familiar
with all
of its parts and functions
before you begin to use it.
Nomenclature
The functioning parts of the Lathe
Duplicator are:
1. Channel-Holds the template
support assemblies and the guard
assembly.
2. Template Support Assemblies-
Support eithera flat templateor an orig-
inal spindle.
3. Guard Assembly-Serves as both
a guard and a
chip deflector.
4. Support Brackets-Clamp to the
way tubes to support the channel.
5. Tool Rest Assembly-Contains the
carbide
cutter and follower. It slides
on the table surface and is
controlled
by handles on each side of its heavy
aluminum base.
6. Follower-Follows the template or
spindle to be duplicated. Must be
the same shape as the carbide cutter.
7. Follower Support-Supports the
plastic follower and mounts to the fol-
lower upright.
8. Follower Adjusting Knob-Permits
the follower support to be raised
and lowered on the
follower upright.
9. Follower Upright-Permits the fol-
lower support to
be adjusted vertically.
10. Cutter Adjusting Knob-Permits
the cutter support to be positioned a
controlled amount
in or out for align-
ment with the follower.
11. Carbide
Cutter-Cuts the work-
piece. Made
of solid carbide, it has an
extremely long life when cutting wood.
It attaches
to the cutter support.
12. Cutter Guide-Aligns the carbide
cutter and also prevents its rotation
during cutting.
13.
Cutter Support-Supports the
carbide cutter and the plastic cutter
guide. Adjusts in or out of the topl
rest.
14.
Handles-Provide a positive grip
that make it easy to guide the tool
rest assembly.
15. Table Assembly-Provides a
smooth surface for the tool rest
assembly.
16. Table
Posts-Permit the table
assembly to
be adjusted vertically in
the carriage.
17.
Spacer-Attaches to the live center
enabling you to turn the full length
of workpieces and to turn short
spindles.
18. Tailstock Live Center
(Optional)-
Not included with the Lathe Duplica-
tor. However it is recommended
be-
cause it provides a frictionless center
for spindle turning. Mounted in the
tailstock, it replaces the cup center. A
spacer supplied with the Lathe Dupli-
cator increases the live center's length
for turning the full length
of work-
pieces and also for turning short
spindles.
Specifications
The specifications of the Lathe Dupli-
cator will give you an idea of its
capabiIities:
Capacities
• Maximum spindle length
-34" with cup center
-33-1/2" with live center and no
spacer
- 32" with live center and
1-112"
long spacer
• Minimum spindle length
-6-1/4" with cup center
-5-3/4" with live center and no
spacer
-4-1/4" with live center and one
spacer
-2-3/4" with live center and two
spacers
• Maximum spindle
diameter-S" with
a flat template, 4" with an original
spindle
• Maximum bowl diameter-S" with a
flat template
• Maximum depth of cut-2-1/4/1
(3-1/4/1 for light freehand cuts inside
bowls)
• Maximum template
length-36/1
• Maximum template thickness-3/S"
• Minimum template thickness-1/4"
(smaller templates only)
Weight-36.5 lb.
Height-47" (when mounted on
Mark
V)
5

Assem bl y and
Setup
Assembly and Setup
NOTE
• Throughout the instructions, ref-
erence numbers appear in paren-
theses following the part name.
These numbers correspond with
reference numbers on the draw-
ings
in this section and the Parts
List section.
• The assembly and setup instruc-
tions for the "Table and Table
Support Assembly" are written
primarily for Mark V Models
500
and 510. If your system is a Mark
II, follow the instructions speci-
fied for Model
500; for a Mark VII,
follow the instructions specified
for Model
500 for mounting the
table supports and Model
510 for
mounting the table posts.
Before any operations can
be per-
formed, you must assemble some
parts, set them up properly, and align
them on the Mark
V. Your safety and
proper use of the Lathe Duplicator de-
pend on your following the Assembly
and Setup instructions exactly, espe-
cially those pertaining to your
specific
Mark V Model. If you're unsure as
to which Model Mark V you own, refer
to the NOTE on page 2.
Tools Supplied: 1/4",5/16" and 7/64"
Allen wrenches.
Tools and Supplies Required: 5/32"
standard Mark V Allen wrench, 9/16"
socket and socket wrench (or 9/16"
wrench), accurate combination square,
straightedge, mineral spiritsand
flooror
furniture paste wax.
Mark V Setup
Set up the Mark V in the lathe mode
according
to the following procedures:
WARNING
Turn off and unplug the Mark V
before you begin any setup
procedures.
The following procedures assume
that the worktable has been
re-
moved, that there is nothing
mounted on any spindles of the
machine and that all alignment
and adjustment procedures spec-
ified
in the Mark V Owners Manual
have been completed_
1_ Attach the three new labels to the
headstock. Remove the three labels
from the headstock and attach the
three new labels at the positions
shown. (See Figure
1.)
2. Mount the drive center on the main
spindle. Slide
the drive center all
the way onto the spindle. With the
5/32" Allen wrench, tighten the set-
screw in the base
of the center so that
the screw rests firmly against the
flat of the spindle.
3_ Mount the tailstock and tailstock
center_ Mount the
tailstock in the base
mount and tighten the accessory
mount lock. Then insert the lathe cup
center or live center assembly in the
tailstock, so that it points toward the
headstock.
WARNING
• If you're using the cup center,
lubricate it with paste wax to
keep it from burning and wear-
ing into the wood causing the
workpiece to loosen on the
lathe_
• Do
not use more than two
spacers with the live center
assembly_
NOTE
• The live center assembly is
strongly recommended for use
as the
tailstock center. The ball
bearing construction allows it
to rotate with the workpiece.
Thus it
won't burn into the wood
and cause loosening of the
workpiece as may sometimes
happen with the stationary cup
center.
• A spacer is supplied with your
Lathe Duplicator
to extend the
length
of the live center assem-
bly for turning the full length
of
the workpieces and turning
short spindles. (See Figure 2.) If
the live center assembly is dif-
ficult to separate, hold the re-
duced diameter end of the shaft
in avise and grasp the head with
adjustable jaw pliers.
Pad the
jaws of both the vise and pliers
to avoid marring the live center.
When you get ready to break down
the lathe mode, you'll probably
find the tailstock center
is stuck
in the tailstock because of the
pressure needed to keep the tail-
stock workpiece securely be-
tween the centers_ If this is the
case, remove the tailstock from
the machine_ Lay the tailstock
over the edge of a workbench so
the eccentric mount
is supported
by the table and the center is
hanging
free_ Tap the back side of
the center with a nylon or rawhide
mallet to pop it
loose_ Hold the
center with your free hand so the
center does not fall to the
floor_
DON'T hit the center with a metal
hammer!
£....,.~~'f.--;;- LABELS
Figure 1. Attach the three new labels to the
headstock.
6

--
Assembly and
Setup
4. Align the lathe centers. (See Figure
3.) Align the drive center and the
tailstock center. (Refer to the Mark V
Owners ManuaL)
Both the drive center and the tail·
stock center must
be directly in
line with each other in order to
properly support a workpiece
so
that it can be turned.
SPACER
~6~ D
~
LIVE CENTER
Figure 2. The spacer extends the length of
the live center assembly.
DRIVE
Figure 3. Both the drive center and tailstock
center must
be directly in line with each
other
in order to properly support a
workpiece.
Tool Rest Assembly
Assemble the tool rest assembly ac-
cording
to the following procedures:
1. Attach handles. Screw handles (52)
securely onto studs of tool rest base
(37).
2. Install the cutter support. Insert the
cylindrical end of the cutter support
(58) into the tool rest base (37) until the
position indicating groove is flush
with the face
of the base. Rotate the
cutter support until the cutter·mount-
ing flat of the
cutter support is paral-
lel with the base. Use the 5/32" Allen
wrench
to tighten the cutter position-
ing setscrew (42) until it firmly
engages the V-groove of the cutter
support, then back off 1/4 turn.
NOTE
Seating the cutter positioning set·
screw in its groove in the
cutter
support will cause the position in·
dicating groove to move slightly
inward or outward from the face
of the tool rest base. Loosening
the setscrew 1/4 turn will allow ro-
tation
of the cutter support and
approximately 1/16" in and out
movement.
3. Install the cutter adjusting knob.
Screw the cutter adjusting knob (51)
into the base (37) until the end of
its screw contacts the back of the cut-
ter support (58).
4. Install the follower upright. With its
flat at the top, and facing toward
the back of the base, insert the follower
upright
(50) into the top hole of the
base (37) until it contacts the cutter
support (58). Use the 5/32" Allen wrench
to tighten the setscrew (41) lightly
against the follower upright.
5. Install the follower adjusting knob
and the follower support. Install the
setscrew
(45) into the knob (44) with the
cup point facing out-of the knob.
Thread the knob with setscrew '"
installed into the follower support (46).
Slide the follower support over the
flat of the follower upright (50) and
tighten the knob.
NOTE
Wiggle the follower support as
you tighten the knob to properly
seat the cup point
of the screw
against the flat of the follower up·
right. When properly assembled,
the setscrew will remain in the
knob when knob is loosened
to
adjust the follower.
.6. Install the carbide cutter and cutter
guide. Attach the triangle carbide
cutter (57), with the bevel down, to the
cutter support (58)
with screw (56)
finger tight. Any of the cutter's three
points or flats may
be positioned as
shown in Figure 4. With the open
slot end of the cutter guide (55) pressed
firmly against a flat side of the car·
bide cutter, use the 7/64" Allen wrench
to attach the cutter guide securely
to the cutter support with screw (53)
and washer (54). Then, securely tighten
the screw (56) of the carbide cutter.
NOTE
Carbide cutters come in four
shapes for a variety of purposes:
•
Triangle: Universal cutter-
rough shaping through medium
detailing . (Included with the
Lathe Duplicator.)
• Round: Initial sh,:.ping, graceful
curves, cove cut>, dishing.
• Diamond: Fine beads, deep in-
tricate details, V-grooves, sharp
corners.
• Square : Square corners,
grooves, straight cylinders,
short dowels and plugs.
TRIANGLE (2 POSITIONS)
I c(@) Gf:®>
DIAMOND
I<®p C@
I (@p~
ROUND SQUARE
Figure 4. Mounting positions of carbide
cutters and cutter guides.
7

Assembly and
Setup
7. Install the follower. Remove the
triangle follower
(49) from the plastic
molding strip. Attach
it to the follower
support
(46) with a screw (47) and
washer
(48).
NOTE
• The profile
of the follower must
match the profile of the cutter.
• SAVE the three extra followers.
You'll need them if you purchase
the round, square and diamond
cutters.
Table and Table
Support Assembly
Assemble and set up the table and
table support assembly according to
the following procedures:
NOTE
In the inverted position, the out-
feed end ofthe table assembly can
be identified by the two screw
holes
·which are closest to the
edge.
1. Attach the table supports to the f
table assembly. (See Figure 5 for Model
500, Figure 6 for Model 510.) With the
outfeed end
of the table assembly (32)
positioned as shown, attach the two
table supports (34) to the table assem-
bly with the four bolts
(33) and washers
(33A) positioned exactly as illustrated.
Finger tighten the bolts just enough to
allow the table supports
to be moved.
NOTE
When positioned correctly, the
distance between post hole cen-
ters
of the table supports should
be 12" for Model
500, 15-1/2" for
Model 510.
BOLTS OUTFEED
END
Figure 5. Table and table support assembly
for Model
500.
/
OUTFEED
END BOLTS
Figure 6. Table and table support assembly
for Model
510 .
2. Install and align the table posts.
(See Figure 5 for Model
500, Figure 6
for Model 510.) Insert both table posts
(35) intothe table supports (34), with the
rack teeth
of the posts positioned as
shown. Make sure
th.e posts bottom out
in the table supports. Align the
flats
of the table posts with a straightedge,
then use the 5/32" Allen wrench to
tighten setscrews
(36) securely.
3. Clean and wax the table posts.
Clean the table posts
(35) with mineral
spirits. Then, sparingly apply floor
or
furniture paste wax on the posts,
and rub it out thoroughly. Use a tooth-
brush or other
stiff brush to remove
any wax residue from the rack teeth
of
the posts.
Use paste
floor wax or paste fur·
niture wax.
Do not use car wax or
spray furniture polish. The table
posts need wax for both protec·
tion and lubricatIon. Car wax of·
fers good protection
for metal, but
it's extremely hard and has little
value as a lubricant. Furniture pol·
ish
isn't hard enough. Paste floor
wax or paste furniture wax pro·
tects and lubricates.
4. Install the table assembly in the
carriage. Place the table posts
in the
carriage mounting holes so that the
racks face toward the headstock
(Model 500) or away from the head-
stock (Model 510). Then gently rock the
table back and forth until you feel
it
settle in place and the pinions engage
the racks. Raise and lower the table
once to be sure the table raising
mechanism operates smoothly. Lock
the table height
lock with the table
near the top
of travel.
DO NOT force the .table up or
down if the table raising "1Tl-3-;ha·
nlsm binds. Carefully lift the table
out of the carriage and inspectthe
racks and pinions
for damage,
dirt, or foreign materials. Also
check that the table posts are in·
serted completely
into the table
supports. Correct any problem be·
fore you
attempt to remount the
table.
5. Tighten the table supports. With
the carriage locked in place, use a
9/16" wrench to tighten the four table
support mounting bolts (33). (See
Figure
7.)
8

Channel and Support
Bracket Assembly
rr
20 "
/'29 :Ji) ,
.';1TJ // -'l/ 0! 25 ;27
~ I ' , ~28
2324
'0-
14
Assembly and ,
Setup
Figure 7, Tighten the four table support
mounting bolts,
Template Support
Assemblies
Assemble and set up the template
support assemblies according to the
following procedures:
1. Assemble the two template support
assemblies. The
two template support,
assemblies (1 thru 8) are preassem-
bled. Remove the
two screws (8) and
washers
(7) from each assembly. Use
the removed screws and washers to
attach each templ at e support assem·
bly
to a bracket (9), making a left-
hand and a right-hand template support
assembly. When installed on the chan-
nel, the template centers must point
toward each other.
(See Figure 8.)
Tighten the screws (8) finger tight. They
will
be tightened securely during
alignment and adjustment.
2. Install the template support assem·
blies on the channel. Loosely assem-
ble a screw (11), washer (12) and
channel nut
(10) (notched side toward
bracket)
to each template support
bracket
(9), then attach each template
support assembly
to the channel (13) at
the approximate
locations shown.
(See Figure 9.) Each channel nut (10)
can be engaged in the channel by
turning the nut parallel to the channel
slot, inserting it through the channel
slot and then turning it clockwise
to a perpendicular position. Another
method of inserting the channel nut is
to remove a cap
(14) from the channel,
engage the channel nut in the channel
and then slide the assembly
into
position. After using either method,
tighten both screws
(11) finger tight.
R.H. TEMPLATE
SUPPORT ASSEMBLY
L.H. TEMPLATE
SUPPORT
ASSEMBLY \ i
' ------"':--+--~
\~~MPLATE
~
• I \ENTERS
Figure 8, Attach each template support Figure 9. Attach the template support
assembly
to a bracket, making a left-hand assemblies, the guard assembly, and the
and a right-hand template support assembly, support brackets to the channel.
"»"-1
<f-2
3-~ : -4 0-:::-14
4-0 I I
:-5
, ,
"" 6
~
': I,
I
"-
'
" 10 19
12 , fl'1
i / ~
11-~ 7-'i' t-
7
22 Guard Assembly
~---">8
21
Te!J1Rlate Support
. Assembly
30-~
,
Table and Table Support Assembly Tool Rest Assembly
~ 4~ ! 47
32
"-'N~
' 50 ~
51
~
41
~
~
,
'~'
~-52 37
~'/-40 ,-53
O- ,- 54
'~5~'-56
i
~57
~8
Spacer
59
0
39~
Note: See Parts List section for Part Numbers and Descriptions of parts,
9

Assembly and
Setup
Guard Assembly
Assemble and set up the guard as-
sembly accordin§
to the following
procedures:
1. Attach the brackets to the guard.
Attach the two brackets (29) to the
guard
(21) with the carriage bolts (31),
washers (30), washers (28) and wing
nuts
(27) . With the hardware at the
back of the guard's two outer slots,
tighten the wing nuts finger tight.
2. Install the guard assembly on the
channel.
In the slot of each bracket
(29), loosely assemble a screw (23),
washer (24), two special washers (25)
and aT-nut (26). Insert the edge of
the T-nut into the channel first, then
pivot the T-nut and push it down into
the channel. Raise the guard all the
way up the bracket and use a 5/16" Al-
Ien wrench
to tighten the screw (23).
Channel and Support
Bracket Assembly
Assemble and set up the channel and
support bracket assembly according
to
the following procedures:
1. Install the two support brackets
and clamps. (See Figure
9.) Place the
channel (13) with the guard and tem-
plate support assemblies attached
across a corner
of your workbench. Use
the 5/16" Allen wrench to attach the
support brackets
(15) to the channel
with screws (19) and washers (20) at
the third hole from each end
of the
channel. Secure a clamp (16) to each
support bracket
(15) with a screw
(18) and washer (17).
NOTE
The placement of the left-hand
support bracket on the channel is
for maximum spindle capacity.
Depending on theoperation being
performed, it should
be moved to
the right as required to provide
more rigid support.
\
\
Figure 10. Securely tighten the clamp .
screws, making certain the
clamps are In
line with the support brackets and that
the clamp recesses are fully engaging the
way tubes.
2. Position the headstock and table
assembly. Move the headstock
to the
full left position and move the table
assembly
to midway between the
headstock and tailstock.
3. Mount the channel and support
bracket assembly on the way tubes.
WA RNING
Have a helper hold the channel
and support bracket assembly up·
right while you tighten the clamps
and hardware.
With the clamps (16) turned to pass
between the way tubes, set the
as-
sembly on the way tubes between the
headstock and tailstock. Engage the
curved recesses
of each clamp against
the underside
of the way tubes and
finger tighten each screw (18).
With the support brackets (15) square
with the channel (13) and seated flat
on the way tubes, securely tighten the
bracket screws
(19) with the 5/16"
Allen wrench. Then securely tighten the
clamp screws (18), making certain
the clamps are in line with the support
brackets and
that the clamp recesses
are fully engaging the way tubes.
(See Figure
10.)
• Do not overtighten clamps.
Overtightening will damage the
way tubes.
• Proper engagement and align·
ment
of the clamps is essential
for accurate front·to·back cen·
tering of the assembly.
Alignment and
Adjustment
NOTE
When you've completed all the
Assembly and Setup instructions,
perform all the procedures in the
Alignment and Adjustment sec·
tion before attempting to operate
your Lathe Duplicator.
,
10

Alignment and
Adjustment
Alignment and
Adjustment
After you've completed the Assembly
and Setup instructions, perform all
the instructions
in this Alignment and
Adjustment section beforeoperating the
Lathe Duplicator.
Also, whenever you remount the
Lathe Duplicator on the Mark V
be sure
to check the "Table to Lathe Centers
Parallelism," "Template Centers Align-
ment," and "Follower to Cutter
Alignment."
The precise alignment of the Lathe
Duplicator is critical for exact duo
plication. If the alignment is not
done properly, you'll waste time
and materials, and find duplicat·
ing extremely frustrating.
Before you begin any
alignment
procedures, make sure your square is
accurate.
(See Figure 1.) Select a wide
scrap board with at least one straight
edge. Place the square against the
edge of the board and draw a line across
the width. Flop the square over and
hold it against the same edge and draw
another line next to the first one. If
the lines are parallel, your square is
accurate.
Cutter Support
Alignment
-Align the cutter support according
to
, the following procedures:
1. Remove the follower support. Loosen
knob (44) and remove the follower
support (46) from the follower upright
(50).
2. Move the cutter guide. Loosen the
cutter guide cap screw
(53) with the
7/64" Allen wrench, and slide the cutter
guide
(55) back toward the base (37).
3. Align the cutter support. Loosen the
two cutter support setscrews (43) using
the 5/32" Allen wrench. Make sure
the cutter positioning setscrew
(42) is
lightly seated in the groove of the
Figure 1. Test your square for "squareness."
cutter support (58). Place an accurate
combination square against the base
(37) and one of the cutter support side
flats. Adjust the
cutter support so
the side flat is against the square.
Tighten the
two cutter support
setscrews
(43). (See Figure 2.) Replace
the follower support on the follower
upright and reposition the cutter guide.
NOTE
Because of possible uneveness on
the top surface of the base, it may
be difficult to achieve perfect
squareness with both side flats.
Therefore, indicate
off one side flat
only.
Figure 2. Align the cutter support.
Table to Lathe Centers
Parallelism
Align the table assembly parallel to
the drive and tailstock centers accord·
ing to the following procedures:
NOTE
Be sure locks are secure, and the
table surface and the bottom sur·
face
of the tool rest base are clean.
1. Align the carbide cutter with the
drive center. Move the table assembly
next
to the headstock. Position the
carbide cutter facing the drive center.
Adjust the table height so that the
upper surface
of the cutter tip almost
touches and is in line with the tip
of the drive center. (See Figure 3.) Lock
the table at this height.
Figure 3. Align the carbide cutter with the
drive center.
2. Check the alignment of the carbide
cutter with the tailstock center. Move
the table next to the tailstock. With the
tip of thecarbide cutter almost touching
the tip
of the tailstock center, check
that the upper surface of the cutter tip
is in line with the tip
of the center.
(See Figure 4.) If the tips are not aligned
properly, raise or lower the tailstock
as required to achieve alignment. Lock
the tailstock. The top surface of the
table assembly is now parallel
to the
drive and tailstock centers.
Figure 4. Check the alignment of the carbide
cutter with the tailstock center.
11

Alignment and
Adjustment
Template Centers
Alignment
Align the template centers according
to the
following procedures:
1. Align the left·hand template center
with the drive center. Move the table
assembly next to the headstock and
lock the carriage. Table height should
be previously adjusted so the top
of
the cutter is level with drive center.
Loosen the template bracket screw
(11)
with a 5/16" Allen wrench and the
two template clamp screws (8) with a
1/4" Allen wrench.
Position an accurate combination
square so that its front edge
just con-
tacts the
tip of the drive center. Care·
fully move the template support
assembly forward on the channel until
the
tip of the template center just
contacts the front edge of the square.
Tighten screw
(11). (See Figure 5.)
Figure 5. Use a combination square to align
the left·hand
template center with the
drive center.
Reposition the square so that its
front edge just contacts the front edge
of the drive center tip. Adjust the tem·
plate support assembly so that the front
edge of the template center tip just
touches
the front edge of the square.
With the square still touching the
edge of both center tips, tighten the two
screws
(8) . (See Figure 6.)
2. Check the alignment at the back
edge
of both center tips. Use the square
to check the alignment at the back
edge
of both tips. (See Figure 7.) If there
is a gap between the tip
of the template
center
(3) and the square, the square
is probably not accurate. Recheck the
front edge
al ignment again. If both
tip edges still touch the square, loosen
both screws (8) and adjust the template
center until
an equal gap is obtained
on both sides
of the tip. Tighten the
screws securely.
3. Align the right·hand template center
with the tailstock center. Move the
table assembly next to the tailstock and
lock the carriage. Then repeat the
procedures
of Steps 1 and 2 to align the
right·hand template center with the
tailstock center.
Figure 6. Use a combination square to align
theedges
of the tips of the left-hand template
center with the drive center.
Figure
7. Check the back edge alignment of
both tips.
Follower to Cutter
Alignment
AI ign the follower to the cutter accora-
ing to the following procedures:
1. Align the follower with the cutter.
(See Figure
8.) Position the carbide
cutter so
its tip is touching the tip of
the tailstock center. Loosen the follower
knob
(44) and adjust the height of the
follower support
(46) so that the tip of
the follower is level with the tip of
the template center (3). Tighten the knob
while wiggling the follower back and
forth. Use the 5/32" Allen wrench to
loosen the follower upright setscrew
(41). Pivot the follower upright (50) until
the tip
of the follower is exactly in-
line with the template center when the
tip
of the carbide cutter is touching
the tip
of the tailstock center. Then,
tighten setscrew
(41) securely. If the
follower and the
cutter do not touch
their respective centers, loosen the two
cutter support setscrews (43) using
a
5/32" Allen wrench. Also loosen the
cutter positioning setscrew (42)
1/2·1 turn. Place a combination square
against the base
(37) and one of the
cutter support side flats. Adjust the
cutter support so the side flat is against
the square and both the cutter and
follower touch their respective centers.
Tighten setscrews (42 and
43).
NOTE
When the follower support is
moved up or down, knob screw
pressure against the flat
of the fol-
lower upright will maintain fol-
lower alignment. Be sura t-c-wiggle
the follower support back and
forth as you tighten the knob.This
will properly seat the cup point
of
the knob screw against the flat of
the follower upright.
Figure 8. Align the follower with the cutter.
12

Templates
Templates
To duplicate turnings, you'll need a
template to follow. For a spindle turning
use either a flat template or
an original
spindle.
(See Figure 1.) If doing a face-
plate turning (bowls or cups, etc.), you
must use a flat template only. Figure 2
shows a spindle template and the fin-
ished product. A faceplate template and
a side view of its product are shown
in Figure
3.
NOTE
You can design yourown templates
or find template patterns
in wood-
working books and magazines.
When designing a template, keep in
mind the capabilities
of the carbide
cutter(s) you own.
To avoid problems
while you'
re turning your project, it's a
good practice to use a detached fol-
lower to check your full size paper pat-
tern to
be sure that the cutter will work
for all contours. For example, if your
template has a deep slot or V-groove, will
the cutter point go in far enough? If
your workpiece has a square in the
de-
sign, be sure that your template is de -
Signed so that the cutter doesn't
contact the rotating corners of the
square section.
Use a suitable marking device to draw
the full size profile on the template
material or on white paper rubber
ce-
mented to the material. If paper is used,
it can
be removed after cutting out
the template or left on. Each template
must have a permanently marked cen-
terline and one or
two end lines to indi-
cate the ends
of the workpiece. (See
Figures 2 and 3.) The template ends to
be clamped should be straight and
square.
Cut out your templates
on a bandsaw
using the 1/8" or 1/4" blade. Sand the
sawn edges smoothly using the pattern
files
on the jigsaw, hand files, emery
board andlor sandpaper.
Your completed
turning will be no better than the tem-
plate that it's copied from and you won't
want rough spots to
be duplicated.
SPINDLE
ORIGINAL
Figure 1. To make duplicate spindles, use a template or an original spindle.
2" 2" 111/2 MAX_ DlA_
HEND LINE END LINE OF FINISHED
~&~~~E+2'
3/8" I- ~1
1/4" DIA_
CENTERLINE HOLE 3/8"
Figure 2. A spindle template and its finished product.
NOTE Template Materials
To help achieve proper template The best ma.terials for your templates
alignment, drill two 1/4" diameter are tempered hardboard, thin closed-
holes
on the centerline, 3/8" from grain hardwoods (such as maple or
each end
of aspindletemplate (See
cherry) and clear or smoked sheet
Figure
2). And drill one 1/4 " diam- acrylics. Maximum template length is
eter hole on the centerline,
318 "
36 ". Material thickness may vary from
from the edge
of a faceplate tem-1/4" for short templates to 3/8" for
plate
(See Figure 3). A 1/4 " dowel longer templates. Clear sheet acrylic
placed through the hole(s)
in the templates have one advantage over
templateclamp(s)
and intothe tem- those made of other materials: they will
plate hole(s) will align the template allow overhead light to shine through,
exactly. illuminating the workpiece.
13

Templates
Making Spindle
Templates
The spindle template should be 4" longer
than the finished product
(a 2" exten-
sion from each end
line)_ For spindle di-
ameters
of up to and including 4", the
width
of the template should be half the
maximum diameter
of the workpiece
plus 2".
(See Figure 2.) For spindle di-
ameters
of from over 4" to 8 ", the back
(straight) edge
of the template can be
no more than 2" from the template cen-
terline. The
front (profile) edge can
protrude 2"
-4 " outward from the center-
line. Drawing perpendicularlinesfrom the
start or end of the spindle contours
to
the centerline is optional, but they may
help you
to better visualize the finished
spindle profile.
If you're making a template for table
legs with a square at the top,
be sure to
measure the distance from the center
of the stock to one corner of the square.
This dimension must
be incorporated
into your template
to keep from cutting
off the corners.
When turning long spindles
with
repeat symmetrical designs from the
ends to the middle, you can get by with
a half template. Just turn one half
of
the workpiece, "flip" it end for end and
then turn the other half.
Pieces longer than lathe capacity,
such as bedposts or clothes trees, can
be made in sections. Design a template
for each section so that the sections
will join in an inconspicuous location
such as at a V-groove
or where two
beads meet.
END
LINE
. ,
,
,
I
1/4" DIA. I
,
,
HOLE
Figure 3. A faceplate template and a side
view
of its finished product.
OUTSIDE
PROFILE
CENTERLINE
INSIDE
PROFILE
CENTERLINE
ACTUAL INSIDE
PROFILE OF BOWL
END
LINE
Making Faceplate
Templates
As shown in Figure 3, the faceplate
template has both the inside and outside
profiles. Only one end line is required
to indicate the outside bottom
of the
bowl. The 1" dimension from the end line
allows for full insertion
into the tem-
plate support assembly. The 1-1/2" and
2" dimensions from the centerline allow
both template clamping setscrews
to
secure the template.
For thin-walled (less than
1/4 ") cups
or bowls, you can make a stronger,
less fragile template by working from
two centerlines-one for the outside
profile and one for the inside.
(See Figure
4.)
Another method of making a bowl _
template is to
cut a 1/4" wide section
through the center of an existing wooden
bowl. When glued
to a suitable piece
of wood for mounting, it makes an ex-
cellent template. You'll lose your origi-
nal bowl but then you can make as
many duplicates as you like.
To cut both profiles without remount-
ing the stock, there may be times when
you'll need sepcuate internal and exter-
nal templates. This will be determined by
your setup, the optional accessories
you're using and how the
~t6 J k is
mounted to the faceplate.
When you're ready for mass produc-
tion
of bowls, specialty chucks are
available which mount to a pin on or
recess in the workpiece. For such work,
you'll need a
chuck mountingtemplate(to
cut the pin or recess) and a profile
template.
In addition to quick mounting
andreleasetimes, thesespecialtychucks
allow you
to produce thinner bottomed
bowls without mounting screw holes.
Figure 4. Template for a thin-walled bowl.
14

Operations
Safety First
I WARNING
Most lathe accidents are caused
by:
improperly mounted work·
pieces, unbalanced workpieces
and improper speed settings.
Each of these factors can cause
a workpiece
to be thrown from the
lathe.
To protect yourself from
injury:
• READ,
UNDERSTAND AND
FOLLOW ALL the information
given in the Safety section be·
fore you perform lathe
operations.
•
You must also READ, UNDER·
STAND AND FOLLOW ALL
the
safety information in the Own·
ers Manual
for the Mark V on
which the Lathe Duplicator is to
be mounted.
Using the Lathe
Duplicator
~~~~~
Be sure that you've performed all
the procedures in the
"Assembly
and Setup" and the "Alignment
and Adjustment" sections before
using
the Lathe Duplicator.
You 'll need to go through a learning
process during your
first several proj·
ects. Read this Operations section,
then begin practicing
with simple proj·
ects such as the one provided at the
end
of this section. The two full size
pattern layouts go together to make
an attractive candleholder. The project
will give you experience in both spin·
die and faceplate turning.
The quality
of the cut in lathe turning
is determined by five factors:
1. The sharpness of the cutter .
2. The right type of cutter for the job .
3. The lathe speed specified for the
operation. The faster the speed, the
better the cut. Do
not exceed the max·
imum rpm recommended.
Lathe Turning Speed Chart*
Size of Stock Rounding Shaping Sanding
Up to 2" dia. C (950 RPM) F (1300 RPM) K (2050 RPM)
2" to 4" dia. B (850 RPM) E (1150 RPM) J (1900 RPM)
4"
to 6" dia. A (750 RPM) D (1050 RPM) H (1600 RPM)
Over 6" dia.
Slow (700 RPM) A (750 RPM) B (850 RPM)
•For Mark V's with 230 v., 50/60 hz. motors, refer to your Mark V Owners Manual
for recommended speeds
4. The aggressiveness
of the way you
use the
cutter . Use a light touch for
initial rounding, a more aggressive
touch when rough shaping and a light
touch for detailing.
5. The height
of the cutter :
•
Cutting above the stock centerline
will usually result in a poor cut by
tearing the wood.
•
Cutting on the stock centerline
generally gives the best results, es·
pecially at the
start of each
operation.
• Cutting from 1/32" to 1/16" below
the
stock centerline sometimes is
better for certain types
of wood.
Lathe Sp eeds
Before you begin any lathe operation,
set the Mark V to run at the correct
speed.
WARNING
Never operate the machine in ex·
cess
of the recommended speed
for the diameter of the workpiece.
The correct speed is determined by
the size
of the stock you're turning;
the operation you're
performing-
whether you're rounding, shaping,
sanding or finishing; and the type
of
wood you're turning. Use faster speeds
as you progress from rounding to
shaping to sanding. Also use faster
speeds with smaller stock. The1arger
the workpiece,
the slower the lathe
speed.
Stock Selection and
Preparation
I WARNING
• Make sure the workpiece does
not have splits, loose knots, or
other defects that could cause
the
stock to break, splinter or
come loose while turning. Never
turn second·hand lumber. If you
hit a nail or screw, you could be
hit by pieces of metal.
• If you're
turning glued·up stock,
make sure
the glue joints are
strong. Glue
the stock and leave
it clamped for at least 24 hours
prior to turning.
• For spindles, alwavs
cut stock
that's more tha~ 3" square into
an octagon usi~ , g the bandsaw.
This removes excess stock,
minimizes imbalance, reduces
vibration and makes turning
safer and easier.
• For faceplate stock, always
cut
the stock round using a band·
saw. This removes excess
stock, minimizes imbalance, reo
ducesvibration and makes turn-
ing the workpiece safer and
easier.
• However your
stock is mounted
to the faceplate, the mounting
surface(s) must be true and
smooth. Use a hand plane or
belt sander for small stock.
When making several bowls
from larger stock, run it through
a
thickness planer before cut·
ting it into circles.
15

Operations
NOTE
• If turning has small diameter
ends, increase stock length to
keep
cutter from contacting
centers.
•
If stock has paraffin on the
ends, cut off the ends.
Balance is extremely important
for
glued-up stock, especially long stock
and stock that is 3" or more in diame-
ter. If you're gluing together
different
types of wood, arrange the wood sym-
metrically. Use one type
of wood in
the center and the same amount
of a
different type of wood on the sides.
Glue the
stock oversize to allow for
balance removal.
Examine each piece
of wood care-
fully, even if from the same type of
tree. Check the density of the annual
rings. Wood with dark annual rings
spaced close together is heavier than
wood with dark rings spaced farther
apart.
To check the balance of your spindle
or faceplate workpiece, first locate .
the centers at each end by drawing two
diagonal lines from corner to corner.
Drive
a, standard 8 penny nail straight
into each center. Use suitable string
to hang the
stock in a level position
from the front bench tube of the
Mark V. The ends of the string should
be looped around the nails. (See Fig-
ure 1.) Gravity
will pull the heavy side
down. Use a jointer, bandsaw or hand
plane to remove no more than 1/32"
at a time from the heavy side until the
stock remains stationary when rotated
to three positions
90 degrees apart.
Locate the lathe centers or the center
of the faceplate
in the nail holes.
Spindle Turning
You can turn duplicate spindles by
using a flat spindle template or by us-
ing
an original spindle such as a
chair rung or
an antique table leg for
the pattern.
(See Figures 2 and 3.)
Set up for spindle turning according
to the following procedures:
NOTE
Initial setup of the channel and
support bracket assembly was
for
maximum spindle capacity. For
shorter pieces, the left-hand sup-
port bracket must
be moved to the
right to allow movement
of the
headstock toward the tailstock.
The
following procedure assumes
that a less than maximum length
spindle is to
be turned.
1. Remove the left-hand support
bracket assembly. Slide the guard
(21)
to the right end of the channel (13).
Use the 5/16" Allen wrench to loosen
the left-hand clamp screw
(18) enough
to disengage the
clamp (16) from
the way tubes. Remove the screw
(19)
and washer (20) attaching the support
bracket
(15) to the channel. Remove
the support bracket assembly and set
it aside. Support the left-hand end
of the channel with your hand.
2. Position the headstock. Position
the headstock so
that the centers are
about 1" farther apart than the length of
the workpiece, and lock the headstock
in position.
3. Remount the left-hand support
bracket assembly. Place the support
bracket assembly to the right
of the
headstock to a position which will not
interfere
with the final position of
the headstock nor with proper posi-
tioning of the left-hand template sup-
port assembly. Install the support
bracket screw
(19) and washer (20) fin-
ger tight, then properly align and
engage the
clamp (16) on the way
tubes. Tighten screw
(19) securely.
Then, tighten screw
(18) securely.
MARK V
WAYT1UBE
1\ )
\J
oil
j
I'-
Figure 1. Check the balance of your
workpiece.
Figure 2. Setup for spindle turning with a
template.
Figure 3. Setup for spindle turning with an
original spindle.
16

I Operations .
Mounting a Spindle
Workpiece
Mounting a workpiece on the lathe is
an extremely important operation.
Improperly mounted stock is danger.
ous and
difficult to turn. To properly
mount a workpiece on the Mark
V, fol·
low this procedure:
WARNING
• If you're turning glued·up stock,
make sure the glue
joints are
strong. Glue the
stock and leave
it clamped for at least 24 hours
prior
to turning.
• Make sure the workpiece does
not have splits, loose knots, or
other defects.
• Always
cut stock that's more
than 3" square
into an octagon
using the bandsaw.
NOTE
To properly support a spindle
c workpiece so that it can be dupli·
cated, both the drive center and
the tailstock center must
be di·
rectly in·line with each other. (Re·
fer to your Mark VOwners Manual
to align the lathe centers.)
1. Find the center of the workpiece.
To mount stock between the lathe
centers, first find the center of the
stock. With a straightedge, draw two
intersecting diagonal lines corner to
corner on each end
of the workpiece.
(See Figure 4.) These two lines inter-
sect at the center of the stock.
2. Seat the lathe centers. Position the
pOints of the drive center and cup
center at the center marks on the
workpiece. Then
hit the centers sharply
with a
plastic or rawhide mallet. (See
Figure 5.)
• To avoid damaging the live cen·
ter bearing, always use the
cup
center for this procedure. The
hole left by the cup center will
accommodate the live center.
•
To avoid damaging the centers,
do not
hit them with a metal
hammer. Use a rawhide or plas·
tic mallet.
When properly seated, the drive
center will leave a hole and four slots
where the spurs bit into the wood.
The cup center will leave a hole and a
small circle. (See Figure
6.)
WARNING
When mounting stock between
the centers, the spurs of the drive
centerand the cup of the cup cen·
ter
must penetrate at least 1/16"
into the stock. Do not use a drive
center, cup center or live center if
the point is damaged. The stock
could be thrown from the
machine.
NOTE
If you're working with hardwood
or
stock that's less than 1-1/2" di-
ameter, drill 1/8" diameter holes
1/2" deep in both ends of the
workpiece, and/or saw diagonal
kerfs1/8" deep. This will help seat
the lathe centers and keep the
stock from splitting when the cen-
ters are driven into it.
3. Mount the lathe centers on the
Mark V. Mount the drive center on
the main spindle and the cup center or
live center in the tailstock.
4. Set the Mark V at the proper speed.
Set the Mark V at the proper speed
and run it briefly.
5. Mount the workpiece. Hold the end
of the stock against the tailstock
center, then extend the quill and mount
the
other end on the drive center.
Figure 4. To find the center of a workpiece,
draw two intersecting diagonal lines corner
to corner on each end of the workpiece.
Figure 5. With a mallet, S8i:1t the drive center
in one end of the workpidce and the cup
center in the other.
Figure
6. When properly seated, the drive
center
will leave a hole and four slots
in the wood, as shown on the left; and the
cup center will leave a hole and a circle,
as shown on
the right. The centers must
penetrate at least 1/16" into the stock.
17

Operations
Press hard against the quill feed lever
to be sure the tips of the drive center
and lathe center are engaged, then
lock the
quill in place.
WARNING
If you're using a cup center, gen-
erouslywax orsoap the end
of the
stock that mounts to the cup cen-
ter. This lubricationhelps keep the
cup center from wearing into the
stock and causing the stock to
loosen on the lathe.
NOTE
• Use as iittle quill extension as
possible.
• If you've mounted a live center
in the tailstock, its ball bearing
construction will permit more
headstock pressure than the
non-rotating cup center.
Mounting a Spindle
Template
Accurate mounting of your spindle
template is essential to prevent inac-
curate diameters, improper position-
ing profiles or unwanted tapering.
To
properly mount a spindle template,
follow this procedure:
1. Adjust the right·hand template
support assembly. Loosen the bracket
mounting screw (11). Use a ruler and the
tool rest assembly to position the
template support assembly so
that the
front edge of the template clamp (5) is
1-1/4" back from the cup
of the tail-
stock center. (See Figure 7.) With the
top edge
of the template support
bracket parallel to the channel, tighten
the screw (11) securely.
NOTE
The template will go 3W into the
template clamp slot. This will
align the template end line, which
is 2" from the end
of the template,
with the end
of the workpiece. If
additional
stock is left on the
workpiece which you intend
to cut
off, adjust the template support
bracket
an appropriate amount
toward the square.
2. Mount the template. Loosen the
mounting screw (11)
of the left·hand
template support assembly. Insert
the
template between clamp (5) and
bracket
(9) of the right·hand template
support assembly, then move the left-
hand template support assembly to
accept the other end
of the template.
Both ends
of the template should
butt up squarely against the spacers
(6). Use the 5/16" Allen wrench to
tighten the left-hand screw (11), keep-
ing the top
of the support bracket
(9) parallel to the channel.
3. Align the template. Align the tem-
plate holes
with the centering hole in
each template clamp (5). (See Figure 8.)
To align the template easily and ex-
actly, insert a 1/4" dowel through the
centering hole in each clamp (5) to
engage the template hole. Use the
5/32" Ailen wrench to tighten the two
rear setscrews (4), one in each tem-
plate clamp.
Mounting an Original
Spindle
If you're using an original spindle such
as a chair rung or antique table leg
as a template,
mount it according to
the following procedures:
1. Rotate the template support assem·
blies. Rotate the template support
brackets 90° so
that the template cen-
ters
(3) are in-line with and pointing
toward each other.
2. Mount the original spindle. Engage
the center hole
of the original spindle
with the right-hand template center
(3). Then move the left-hand template
support over
to engage its template
center in the other end
of the original
spindle. Loosen the two wing nuts
(1), then use a medium, flat-bladed
screwdriver in the slotted end of each
template center
to turn the centers
in
to secure the spindle. Tighten the
wing nuts.
Figure 7. Adjust the right-hand template
support assembly.
CENTERING HOLE
TEMPLATE
CENTERLINE
Figure 8. Align the template
NOTE
" The template centers must pen-
etrate the center holes
of the
original spindle at least 1/8"
with enough pressure to keep
the spindle from rotating.
.. The ends of the original spindle
must be flush with the ends of
the workpiece. After mounting
the workpiece, readjust the tem-
plate centers
as required to shift
the original spindle into end-to-
end alignment with the
workpiece.
.. If you are duplicating an original
spindle with square corners,
then you MUST position the
original spindle with the square
corners pointing at the follower.
18

Operations
Duplicating a Spindle
Duplicate a spindle according to the
following procedures:
WARNING
• Keep the guard in place when·
ever you're performing turning
operations.
c Do not exceed recommended
speeds.
• Periodically turn
off the Mark V
and check that the workpiece
remains securely mounted.
•
Do not allow the cutter to come
in
contact with parts of the du-
plicator or Mark V.
1. Position the guard assembly. Place
the tool rest assembly on the table
in a cutting position, then adjust the
guard to
be as close as possible to
the workpiece
without interfering with
the rotation of the workpiece or the
movement
of the tool rest assembly
underneath it.
WARNING
Keep the guard in place during all
turning operations.
2. Make a five·point check. All five
locks-headstock, carriage, table
height, quill,
tailstock-must be
secure.
S. Move the table and guard. Move the
table and guard to the right-hand
end
of the workpiece. Lock the table.
4. Adjust the height of the follower if
required. The follower should be posi-
tioned so
it's at the center of the
template edge or
at the center of the
original spindle.
If adjustment is re-
quired, loosen the follower adjusting
knob
(44) and lower or raise the fol-
lower support. Retighten the knob se·
curely. Wiggle the follower as the
knob is tightened
to properly seat it.
.,
5. Develop a firm grip on the tool
rest assembly. Before turning on the
lathe, determine
the best method
of gripping the tool rest assembly. De·
pending on your hand you may
find it necessary to grip each knob with
all five fingers or to grip each knob
with four fingers with your thumbs
wrapped around the back of the tool
rest.
WARNING
When gripping the tool rest as·
sembly,
do not extend yourfingers
beyond the front face
of the tool
rest base.
6. Round off the workpiece. Check
that the proper speed has been set,
then turn on the Mark
V. Roughly
round
off the corners of the workpiece
by cutting small areas
at a time. (See
Figure 9.) Start at the right-hand end of
the workpiece. When each small area
becomes round, you will feel less
vibration and hear a change in the
noise level.
After the first area is rounded,
cut
subsequent small areas from left to
right (from the octagon surface to the
rounded surface). When you are turn-
ing a long workpiece and the part
of the workpiece that's over the
table
is rounded, turn off the machine and
move the table and the guard to the
left. Brush
off the table and tool rest,
then check that the workpiece is still
mounted securely.
Turn on the machine
and, to reduce vibration, finish
off
the rounding procedure by working
from the left-hand end
of the work-
piece.
Increase the speed dial setting from
rounding to shaping, and then turn
off the machine.
7. Offset the carbide cutter. Because
the follower will
be guided against
the template to make the rough shap-
ing cut, the carbide
cutter must be
backed
off from 1/64" to 1/32" from its
aligned position to leave enough extra
stock for final detail shaping.
Loosen the
two setscrews (43) which
secure the
cutter support (58). Then
loosen the position indicating setscrew
(42) 1/4 turn. Back off the adjusting
knob
(51) one-half turn to allow the
Figure 9. Roughly round off the corners of
the workpiece by cutting small areas at a
time.
cutter support to be moved back 1132"
(a one-quarter turn will allow 1/64"
movement). Move the cutter support
back until
it contacts the stud of
the cutter adjusting knob.
Align the cutter support according
to "Cutter Support Alignment" in the
Alignment and Adjustment section.
When tightening the
cutter support
setscrews
(43) during adjustment,
press the
cutter support against the
adjusting knob stud instead
of using
the position indicating setscrew (42) in
the groove
of the cutter support.
NOTE
Because
of the ct:+!er offset, you'll
be cutting away less stock than
on your template. But when you
work down an edge like a cove or
around a bead, the cutter offset
does not compensate for side-to-
side adjustment. So
if you go
straight in, down a shoulder, the
follower will go to the exact po-
sition (final dimension).
To avoid
this, keep the follower perpendic-
ular to the profile area
of the tem-
plate. (See Figure
10.)
After you've become experi-
enced in handling the tool rest as-
sembly, backing
off the carbide
cutter won't
be necessary. You'll
be able to guide the follower near
the pattern
without making con-
tact, down to a final gap
of about
1/32".
19

Operations
Figure 10. Keep the follower perpendicular
to
the profile area of the template.
Figure 11. When the follower makes gentle
contact with
all the large contours of the
template, rough shaping is completed.
8. Rough shape the workpiece. Move
the table and guard to either end of the
workpiece.
Lock the table. Check
that the proper speed has been set,
then turn
on the Mark V.
Start cutting the larger diameters
first, then work on the smaller diame-
ters. Don't force the cutter into the
stock. Work
it in gradually, using a back
and forth motion
in one small area
at a time. If cutting a V-groove, work
into it-don't go straight in.
Turn
off the machine, then move the
table and guard to the other end
if
necessary to finish the rough shaping.
Brush
off the table and too/ rest
and check that the workpiece is
~till
mounted securely before turning on the
machine again.
When the follower makes gentle
contact with all the large contours of
the template, rough shaping is com·
pleted.
(See Figure 11.) Increase the
speed dial
setting for detail shaping,
and then turn
off the machine.
9. Reposition
the cutter support.
Loosen the two setscrews (43) which
secure the
cutter support (58). Then
readjust the
cutter support flats ac·
cording to
"Cutter Support Alignment"
in the Alignment and Adjustment
section.
NOTE
If you used a
thick carbide cutter
for rounding and rough shaping,
and you change to a thinner cutter
for detail shaping, you'll need to
raise the table
slightly to center
the thinner
cutter on the work·
piece centerline and lowerthe fol·
lower support to center the
follower on the template edge or
the original spindle centerline.
10. Detail shape the workpiece. Move
the table and guard to either end of
the workpiece. Lock the table. Check
that the proper speed has been set
then, turn on the Mark
V.
NOTE
Because detailing cuts are less
"aggressive," you'll need to
quickly switch attention between
the
cutter and the follower to
maintain uniform spacing be·
tween the follower and template
and to watch the cutter's action.
Cut in much the same manner as
you did in rough shaping,
except cut
"downhill" when turning the transition
from the square
of the spindle to a
round profile.
. When shaping beads and coves,
cut
In an "uphill" direction. (See Figure 12.)
Turn off the machine, then move
the table and guard to the other end
to
finish the detail shaping. Brush ott
the table and tool rest, and check that
the workpiece is still mounted
Figure 12. When shaping beads and coves
cut in an "uphill" direction. '
securely before turning on the machine
again.
When the follower makes
contact
with all the contours of the template,
detail shaping is completed. (See
Figure
13.) Turn off the machine and
inspect your finished piece.
Spindle Turning Tips
• To turn a straight cylinder, use a
straightedge as your template.
Mounting it off center at one end
will give you a tapered cylinder.
• If your spindle
will have a pin which
needs to
fit a hole diameter exactly,
first turn a trial piece. Check the
diameter and readjust the template
if necessary. Such a piece requires a
very precise template set~;~). Cut
beyond the pin
length te allow for
cutott.
e If you're using two different cutters
for extensive production runs, round
off and rough shape all your spin·
dies
at one time. Then change cutters
to do the detail shaping
of all. Or
you can use two tool rest assemblies,
each set up for a different cutter,
to turn out one spindle at a time
without cutter changeover delays.
• Do
not push the follower against the
template. Use a very
light touch to
follow the template and make final
cuts.
e Practice makes perfect. Expect to
make some mistakes. Practice on
scrap
stock before attempting a
project with expensive hardwood.
20