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
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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.
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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.
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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.