woodcut Bowlsaver Max4 User manual

Bowlsaver
Max4
U S E R G U I D E
Max4 User Support Video available
at www.woodcut-tools.com in the
Support tab.

W o o d c u t T o o l s w a s e s t a b l i s h e d f r o m a p a s s i o n f o r w o o d t u r n i n g .
I n t h e 1 9 7 0 ' s W o o d c u t T o o l ' s f o u n d e r K e n P o r t o w n e d a n d
o p e r a t e d a s o u v e n i r b u s i n e s s i n N o r t h l a n d , N e w Z e a l a n d . K e n
o f t e n t u r n e d m a n y o f t h e w o o d e n s o u v e n i r s h e w o u l d l a t e r s e l l .
F r u s t r a t e d w i t h t h e w o o d t u r n i n g t o o l s a v a i l a b l e t o h i m K e n
r e s o u r c e f u l l y d e s i g n e d a n d d e v e l o p e d a p o r t f o l i o o f w o o d t u r n i n g
p r o d u c t s . T h e t o o l s w e r e p r i m a r i l y d e s i g n e d f o r h i s o w n u s e , a n d
f o r h i s n e t w o r k o f f e l l o w t u r n e r s w h o a s s i s t e d h i m w i t h f e e d b a c k
t o r e f i n e t h e d e s i g n . T h i s w a s K e n ’ s a p p r o a c h f o r a l m o s t 2 0 y e a r s
u n t i l h e d e v e l o p e d t h e c o n f i d e n c e t o m a k e h i s w o o d t u r n i n g
p r o d u c t s a v a i l a b l e f o r a n y t u r n e r f r o m 1 9 9 0 . K e n w a n t e d t o m a k e
i t a s e a s y a s p o s s i b l e f o r c u s t o m e r s t o e n j o y t h e i r t u r n i n g
e x p e r i e n c e , b y t a k i n g t h e t o o l , p u t t o w o o d a n d s e e t h e s h a v i n g s !
T o d a y t h e c o m p a n y i s s t i l l l o c a t e d i n N e w Z e a l a n d a n d i s
c u r r e n t l y o w n e d b y t h e H e w i t t f a m i l y . K e n r e m a i n s a c t i v e l y
i n v o l v e d i n p r o d u c t d e s i g n f o r W o o d c u t T o o l s .
W e a r e d r i v e n b y t h e d e s i r e t o g i v e c u s t o m e r s t h e b e s t q u a l i t y
p r o d u c t s w i t h n o c o m p r o m i s e s . O u r a p p r o a c h i s t o w o r k c l o s e w i t h
t h e w o o d t u r n i n g c o m m u n i t y , l i s t e n i n g t o c u s t o m e r s i n c l u d i n g
p r o f e s s i o n a l t u r n e r s a n d t a k i n g t h e t i m e t o e n s u r e t h e p r o d u c t i s
r i g h t . F o r t u n e r s , b y t u r n e r s .
W o o d c u t T o o l s b r e a k s a w a y f r o m t h e c u r r e n t t r e n d o f c h e a p , l o w -
q u a l i t y p r o d u c t s b y i n t e g r a t i n g t o g e t h e r a m i x o f t r a d i t i o n a l
m e t h o d s a n d m o d e r n t e c h n o l o g y .
A n e m p h a s i s o n t r u e c r a f t m a n s h i p a n d c o n t i n u o u s i m p r o v e m e n t .
I n k e e p i n g w i t h W o o d c u t T o o l s v a l u e s o u r o b j e c t i v e i s t o a l w a y s
o f f e r t h e b e s t p o s s i b l e p r o d u c t . W i t h c u s t o m e r f e e d b a c k o n t h e
M a x 3 t h e W o o d c u t T o o l s t e a m d e c i d e d t o i m p r o v e o n t h e M a x 3
w i t h a n e v e n b e t t e r d e s i g n .
I n c o l l a b o r a t i o n w i t h K e n P o r t a n d a n i n t e r n a t i o n a l t e a m o f
t u r n e r s , W o o d c u t T o o l s h a v e d e s i g n e d , t e s t e d a n d d e v e l o p e d ,
o v e r m a n y y e a r s , t h e l a t e s t b o w l c o r i n g p r o d u c t , t h e M a x 4 .
PRODUCT BACKGROUND
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
ABOUT WOODCUT TOOLS
2

W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
BOX CONTENTS
3 x Hex keys
3 x Handle Clamp socket cap screws
Tailstock Support Rod wingnut and flat washer
Tool Post lock washer and screw
8.Kit bag items
9.User Guide
10.Blade Templates
11.Tool Post may be included
(Additional purchase)
1.
2.
3.
4.
5.
6.
7.
8.
9.
3
10.
10.
11.
Base Plate and Blade Holder
Handle Clamp
Max, Large and Small Blades
3/8" Tailstock Support Rod
Morse Taper
20" Handle with 5/8"
Handle Spigot Rod
1.
2.
3.
4.
5.
6.
7.

1. Hand screw the Shaft s p i g o t into th e Handle Cl a m p , you wi l l need to
tighten with a wrench.
6 .
.
ASSEMBLY
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
5 .
.
2. A t t a c h your Tool P o s t to the Bowlsaver M a x 4
Base Plate using the Tool Post Screw and Lock
Washer, found in the kit bag.
Then screw the Ha n d l e Clamp into the
Handle, tightening screws with Hex keys in
your kit bag.
4
3. Attach t h e Morse T a p e r
to the Bo w l s a v e r Ma x 4
Base Plate.
N o t e : F o r o p t i m u m s t a b i l i t y e n s u r e y o u r T e n o n ,
B o w l s a v e r P i v o t P o i n t a n d T a i l s t o c k S u p p o r t R o d
a r e a l l a l i g n e d . S e e y e l l o w l i n e b e l o w .

Max Bla d e
Lar g e B l ade
3. Position the Tool Post so the Blade cutter is
centered with the point of the drive spur, or slightly
above as il l u s t r a t e d (this assumes that when th e
Blade is extended in the E n d Gr a i n of th e wood that
the Blade is now at center). Tighten the Tool Rest
locking handle. Slide the shaft collar down the
support post and then tighten the grub screw.
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
LATHE SET UP
1.Mount the Ma x 4 Tool onto the Tool Re s t . Do not connect t h e Morse taper
to the Tail Stock at this stage.
2. Place a Max4 Blade into the Blade Holder and fasten the
Handle Cl a m p using the th r e e Socket Head Ca p Screws and Hex
key all found in the kit bag.
Sma l l
Bla d e
The largest blade goes on th e outer si d e of th e
Blade Holder and should be positioned between
the two roller bearings. Ensure the Max bl ade is
resting on the wear pad before assembling t h e
Handle Clamp.
The large blade in the middle slot and smallest on
the inner sl o t . Ensure th e blade is resting o n the
wear pad before assembling the Handle Clamp.
Please note: Never core with more than one
blade at a time.
5

W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
PREPARING THE WOOD BLANK
Bring t h e Bowlsaver Max4 up to
the wood and measure where it will
cut.
Included with your Bowlsaver
Max4 a r e Templates designed t o
plan your nest of bowls.
A l t e r n a t i v e l y , you ma y use wide
calipers to check the distances and
therefore ensure correct bowl
thickness.
To make this planning s t a g e even
simpler Woodcut Tools has an
optional Bowlsaver Max Light
Guide.
Essential to h o l d i n g the wood o n the lathe i s making a S p i g o t , also referred
to a s a Te n o n , or Chuck Bite. It is imp o r t a n t that this Spi got is ma d e to the
correct size and shape.
Please refer to Page 9 for further information.
Remount the bowl blank in the Chuck.
Cut a Spigot on t h e fa c e (top of the bowls) s i d e so that you can remount t h e
wood after each bowl is saved.
The bowl wall thickness will depend on how dry the wood is.
6

W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
Set the initial lathe speed between 300 to 400rpm, slower with larger and
dry blocks. Push t h e blade of the Bowlsaver M a x 4 gently i n t o the wood. If
the flow of shavings stops, then p u l l the b l a d e back t o enable t h e
shavings t o flow out. Increase the l a t h e speed as the cutting t i p
moves cl o s e r to the ce n t r e of the pr o j e c t . 'Feel your wa y ' as you co r e
adjusting lathe speed and releasing the wood shavings.
If you notice the wood shavings changing from shavings to dust the blade
cutter ha s probably lost it s sharpness and we therefore recommend
sharpening the f r o n t of the cutter with a diamond h o n e . Pl e a s e se e the
previous section 'Maintaining cutter sharpness'
BEGIN CUTTING
The Bowlsaver Max4 is designed to cut in an exact se m i - c i r c l e which has a
radius that you can measure from the central rotation post of the Max4.
Do a final check th a t all connections are tight. It is good pr a c t i c e t o c h e c k
this each ti m e just prior to cutting. W o o d c u t Tools always re c o m m e n d s the
use of a Woodturning helmet and ear protection when coring.
PREPARING TO CUT
With the Bo w l s a v e r M a x 4 i n it’s cutting position, tighten the Tool Rest
locking handle onto the support post.
Leaving everything loose b r i n g the t a i l stock u p to t h e Morse T a p e r . Insert
the Tailstock support rod a n d pull the Morse Taper i n tightly securing the
Morse Taper into the T a i l Stock using t h e F l a t Washer and W i n g Nut found i n
your k i t bag. L o c k the Tail St o c k into position. Lock th e indexing lever
under the Tail Stock taper.
7
The M a x4 is he l d b y a 3 / 8” UN C d i am e te r
th r ea d ed ro d t o s e cu r e d ur i ng co r in g .

3. Whether you start with t h e large or small bowl will
depend o n your pr e f e r e n c e for remounting a n d
finishing each bowl.
It is possible to core bowl 2 and then bowl 1 and rely
on a vacuum chuck or other mounting sy s t e m to finish
bowl 1. Or, y o u can c u t bowl 1 , then r e m o u n t that
saved blank on the Face Pl a t e and cut a Spigot as you
did fo r t h e first, larger, block. Then remount th e wood
by the Spigot and use the Max4 to cut bowl 2.
4. To cut a bowl from a 550mm ( 2 2 " ) bowl blank the
Max4 is positioned towards the op e r a t o r . Note how
the cu t c u r v e s towards the face of th e b l o c k as it
approaches the ce n t r e l i n e . B o t h bowls will be
relatively flat bottomed when finished.
Woodcut T o o l s recommends a m i n i m u m chuck size of
125mm (5") for a bowl blank in excess of 375mm (15").
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
PLANNING MORE BOWLS
1. To save a bowl fr o m a 35 0 m m (14") bo w l blank th e
Max4 is set just a l i t t l e beyond the c e n t r e line of the
lathe. The o u t s i d e bowl h as an initial w a l l thickness o f
25mm (1") and w i l l require some c h i s e l work if the
inside is to follow the outside curve.
2. To core tw o bowls from a 45 0 m m (18") bowl blank,
the Max4 is positioned towards the operator from the
centre line for bowl 1 and almost on the centre line,
but away from the work face, for bowl 2.
350mm bowl blank
Medium blade
450mm bowl blank
2 = Medium blade
1 = Large blade
550mm bowl blank
Large blade
8

6 .
.
Essential to ho l d i n g the wood on the la t h e is ma k i n g a Spigot, also r e f e r r e d
to as a Tenon, or Chuck Bite. It is im p o r t a n t that this Spigot is made to t h e
correct size and shape.
Woodcut Tools recommends a minimum 4” or 100mm Spigot is ma d e . La r g e
Dovetail jaws are r e c o m m ended to hold the project o n the lathe, rather
than standard jaws a n d creating a recess. A recess can p u s h the wood
apart, r a t h e r than pull t o g e t h e r . It’s important that t h e entire Spigot is
gripped by the Chuck Jaws.
A Four Jaw Ch u c k se t of 15 0 m m (6 ” ) to 20 0 m m (8”) is recommended if your
wood blank is over 500mm (20”) diameter,
The diameter of the Spigot sh ould be ab o u t th e sa m e as th e in s i d e di a m e t e r
of the C h u c k Ja w s . This means t h a t th e Chuck Jaws w i l l be in contact w i t h
the wood around the circumference of the Spigot.
It is also important t h a t there is c o n t a c t between the C h u c k Jaws and w o o d
at the base of th e Spigot, wi t h the narrow edge of the Jaws pr e s s i n g on
the wood.
You wil l fi nd a d et ail ed v ide o on c re ati ng a s pi got
at www.w ood cut -t ool s.c om in th e S up por t T ab .
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
PREPARING THE SPIGOT
9
BOWL SHAPE
To change t h e shape of the base of the bowl s i m p l y slide the Tailstock
along the trac k o f y o u r M a x 4 to achieve the shape you require.
To change the shape of the top of
the wall of the bowl you are coring
we recommend you core a t h i c ker
wall with your Max4 and then use
your B o w l Gouge to achieve the
shape you requ i r e .
Please be aware that a d j u s t i n g the
Bowlsaver p i v o t point fr o m being
aligned with t h e t e n o n a n d t a i l stock
may r e d u c e t h e stability of the
product when c o r i n g .

6 .
.
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S 1 0
CORING HARD/DENSE WOOD
Coring hard, dense wood will be more of a challenge than coring wet wood.
Woodcut Tools recommends a n app r o a c h to coring hard, d e n s e wood to
firstly ensure the fron t of the cutter is sharp with a diamond hone. You may
need to sharpen the f r o n t of t h e cutter m u l t i p le times during a single bowl
core. You w i l l n o t ice the cutter is becoming dull when t h e w o o d shavings
turn to dust. S o m e production turners also create a small negative rake on
the top edge o f t h e f r o n t of the cutter, to soften the front edge.
In general Woodcut Tools recommends setting up the Max4 so the blade tip
is centred with the point of the drive spur. Some production turners prefer
to set the bl a d e t i p a b o u t 10mm above center.
For o p t i m u m stabi l i t y ensure y o u r Tenon, Bowlsaver P i v o t Point and t a i l s t o c k
are all aligne d . R e f e r t o i l lustration on page 4.
Al tho ugh you can op era te t he B owl sav er Max4 wi th e ith er s eas one d dry wood or
we t/g ree n wood , ma ny tur ner s will do the ir b owl sa vin g with wet /gr een wo od a nd
th ere for e m ake an al low anc e f or shr inkage of the wo od dur ing th e d ryi ng pro ces s.
When c o r i n g hard and dense
wood there is a risk of
binding and the lathe
stalling. This can be
prevented by cutting a wide
channel on the inside o f the
bowl to create more
clearance for the cutter.
Create the wi d e r c h a n n e l b y
backing ou t of a cut to cl e a r
chips, then pull s l i g h t l y on
the cu t ter when going back
to the cut and then retract
and push on the cutter bar
getting back to the cut. This
provides an extra 1/64"
clearance on e a c h s i d e .
Start the la t h e a t a b o u t 300 rpm and feel your way increasing the lathe speed
as you reach ce n t e r . To make the process easier, some tu r n ers soak th e wood
to be cored i n w a t e r f o r w eeks, or months before bowl coring.

Check that the S t e l l i t e cutting t i p s have n o t been d a m a g e d during h a n d l i n g
or assembly.
@ woodcuttools
#bowlsavermax4
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
MAINTAINING CUTTER SHARPNESS
When coring wet wood th e cutter
may last several c o r e s before
needing to be re sharpened. For
hard, d e n s e wood e . g . Burr Elm
you may need to sharpen the
front of t h e cutter m u l t i p l e times
during a single bowl core.
1 1
Email support @ woodcut - tools.com
Please subscribe to our Woodcut Tools
YouTube channel, Facebook and
Instagram pages, to stay up to date with
our latest product videos.
U S E R S U P P O R T
H O W O F T E N T O S H A R P E N T H E C U T T E R :
The Woodcut Tools Bowlsaver M a x 4 cutter is made f r o m Stellite which i s
also used i n the Saw M i l l i n g industry because o f it’s unique a b i l i t y to retain
an edge for a long time.
H O W T O S H A R P E N T H E C U T T E R :
Sharpen the front fa c e of the tip with
the Woodcut T o o l s Diamond Hone o r
similar product, 5° to 15°. Only grind
the to p of the cu t t e r if you wish to
change the d o w n w a r d s rake. Do n o t
sharpen the sides.

G E N E R A L S A F E T Y G U I D EL IN ES
W O O D C U T - T O O L S . C O M  | @ W O O D C U T T O O L S
Woodcut Tools recommends these guidelines to ensure your safety.
1. Please read this user guide before operating this product.. Ensure you are familiar with the product ' s application and limitations plus the specific
hazards peculiar to it.
2. Wear safety glasse s. A full face mask is recommended. . Safety glasses ( must comply with ANSI STANDARD Z87.1 USA ) Everyday eye glasses usually
are only impact resistant ; they are not safety glasses. Also use face or dust mask if cutting operation is dusty.
3. Wear appropriate clothing . Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewellery, which may get caught in moving parts.
Non - slip footwear is recommended. Wear protective hair covering to contain long hair.
4. Use ear protectors . Use earmuffs for extended period of operation. Use muffs rated to 103 DBA LEQ ( 8 hr ) .
5. Do not operate in a high risk environment. . Don ’ t use power tools in damp or wet locations, or expose them to rain. Keep work area well lighted.
6. Ensure the work area is clean. Cluttered areas and benches invite accidents. Build up of sawdust is a fire hazard.
7. Keep children and visitors away. All children, infirm and visitors should be kept a safe distance from work area.
8. Ensure the workshop is childproof with locks, master switches, or by removing starter keys.
9. round all tools . If the tool is equipped with a three - prong plug, it should be plugged into a three hole electrical receptacle. If an adapter is used to
accommodate a two - prong receptacle, the adapter lug must be attached to a known ground. Never remove the third prong.
10. Ensure the tool is disconnected from the power suppl y while the motor is being mounted, connected or reconnected.
11. Disconnect tools from wall socke t before servicing and when changing accessories such as blades, bits, cutters and fuses.
12. Prevent accidental starting . Make sure switch is in the Off position before plugging in power cord.
13. Never leave machine running unattended . Do not leave tool unless it is turned off and has come to a complete stop.
14. Keep guards in place and in working order.
15. Use the correct tool . Do not use a tool or attachment to do a job for which it was not designed.
16. Use recommended accessories . The use of improper accessories may cause hazards.
17. Don ' t force the tool . It will do the job better and be safer at the rate for which it was designed.
18. Maintain tools in optimum conditio n. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing
accessories.
19. Avoid standing on the tool. Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted.
20. Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting wrenches are removed from tool before turning it
on.
21. Don ' t over reach . Keep proper footing and balance at all times.
2 2. Direction of feed . Feed work into a blade or cutter against the direction of rotation or the blade or cutter only.
23. Attention to work. Concentrate on your work. If you become tired or frustrated, leave it for awhile and rest.
24. Secure work . Use clamps or a vice to hold work when practical. It ’ s safer than using your hand and frees both hands to operate tool.
25. Check for damaged parts . Before further use of the tool, any part that is damaged should be carefully checked to ensure that it will operate properly
and perform its intended function. Check for alignment of moving parts, binding of moving parts, mounting, and any other conditions that may affect its
operation. Any damaged part should be properly repaired or replaced.
26. Drugs, alcohol and medication. Do not operate tool while under the influence of drugs, alcohol or any medication. 27. DUST WARNIN . The dust
generated by certain woods and wood products can be harmful to your health. Always operate machinery in well ventilated areas and provide for proper
dust removal. Use wood dust collection systems whenever possible.
W A R R A N T Y T E R M S
Woodcut Tools are guaranteed against faulty workmanship and faulty materials for twelve months from date of purchase. Fair wear and tear excluded.
We will replace or repair any tool returned to the supplier or factory free of charge. Freight to and from the factory will be at the expense of the purchaser.
Woodcut Tools Limited
Hawkes Bay
New Zealand
[email protected]