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BIG UPDATE III----SHOPMADE HELICAL CUTTERHEAD

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Blog entry by alanealane posted 2184 days ago 3304 reads 1 time favorited 13 comments Add to Favorites Watch

Well, it’s installed in the planer. Watch the videos below to see how things turned out. I still haven’t finished editing the machining video, but I’ll get to it.

See my first Topic SHELIX CUTTERHEAD
and Part I and Part II of this blog entry

Here I begin inserting the teeth.

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...and here I finish. I didn’t want to bore you with watching me insert every tooth.

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Here is the first time I actually power up the planer. Pretty intimidating, if you ask me. I was ready to run for the hills !!!

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FANTASTIC!!! There was virtually NO AIR TURBULENCE!!! The flat knives in the original cutterhead blew quite a breeze from the front of the planer, but with these…ah, there was no breeze!!! And the noise level is much easier on the ears (even though I do wear ear protection). I think a planer with an induction motor instead of my universal motor would really be whisper quiet.
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The first board planed…Quite interesting results…

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WOULD YA LOOK AT THOSE PURDY LITTLE SHAVINGS COMIN’ OUT!! Way better than big wide ones that clog up my underpowered dust collection system.

PLEASE PAY NO ATTENTION TO MY INCREDIBLY MESSY SHOP…LOL
...although…the lumber rack is ok! ;-D
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You can see that there is a re-design called for. A slight adjustment in the tooth angle. When each tooth reaches the very lowest point in its rotation, each corner of the tooth should be at the exact same height. That will solve the problem.

But I think that zig-zag cut could be used to make some interesting moulding… Thanks to everyone for supporting me and giving such kind comments!!!

-- Lane Custom Guitars and Basses



13 comments so far

View motthunter's profile

motthunter

2141 posts in 2401 days


#1 posted 2184 days ago

what a cool project. Keep us in the loop. I am enjoying your work

-- making sawdust....

View FlWoodRat's profile

FlWoodRat

732 posts in 2511 days


#2 posted 2184 days ago

Alan, how could you possibly consider your effort a failure? You successfully designed a cutter head that”
Did in fact remain in one piece at high speed, did cut the wood to an even depth and more importantly, you learned more about the challenges of design and manufacturing. Now you get to exercise your mental skills to re-design and remanufacture it. Kudos to you for your efflorts. Keep up the good work lad.

-- I love the smell of sawdust in the morning....

View SteveKorz's profile

SteveKorz

2130 posts in 2316 days


#3 posted 2184 days ago

No way a failure… Brilliant if you ask me. Keep your head on straight and you can go places with a mind like that.

-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †

View Greg Wurst's profile

Greg Wurst

778 posts in 2435 days


#4 posted 2184 days ago

The concept works, so once you refine the angles I think you will be good to go. Good luck!

-- You're a unique and special person, just like everyone else.

View Bigbuck's profile

Bigbuck

1347 posts in 2266 days


#5 posted 2184 days ago

Wow, nice job you certainly did better than I would have.

-- Glenn, New Mexico

View Zuki's profile

Zuki

1404 posts in 2679 days


#6 posted 2181 days ago

Great job thus far. Looking forward to Phase II.

-- BLOG - http://www.colorfulcanary.com/search/label/Zuki

View Kaytrim's profile

Kaytrim

56 posts in 2178 days


#7 posted 2149 days ago

Alan, you need to stagger the teeth on the cutter head so each row cuts a slightly different path. The way you have things setup now is that each tooth is in locked step behind the other. Set your teeth like you would bricks in a wall. Then you will get a nice smooth board. Don’t give up you are on the ‘cutting’ edge with your design.

View gerald's profile

gerald

1 post in 2030 days


#8 posted 2030 days ago

are you going to make one for a 755

View Scott Bryan's profile

Scott Bryan

27251 posts in 2424 days


#9 posted 2030 days ago

I have to agree that this is in no way a failure. I have enjoyed following this series and, in fact, was wondering where you were with it. Some minor redesigns and you should be good to go. Keep us posted on what is going on. I think it is really cool.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View Karson's profile

Karson

34861 posts in 3003 days


#10 posted 2030 days ago

It looks to me, by your video picture that the wood is cut at an angle. How is the redesign coming along. On my Grizzly cutterhead the space between the teeth are about 1/2 a cutterhead width. so the next spiral cuts the wood left with the first row.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View alanealane's profile

alanealane

365 posts in 2493 days


#11 posted 2030 days ago

gerald, the DeWalt 755 is a bench grinder…Sorry, no can do LOL :-P

Honestly guys, I haven’t touched the design for about 3 months. I’ve hardly even been on the LJ site…SHAME ON ME!! I’ve been building my recording studio and improving my chops on the keys, guitar, and bass.
But it’s time to get back in the shop, I think.
I know what needs to be done, I just haven’t written the CNC code to machine the new part yet.
Presently, each row of teeth DOES overlap the next row, so that in theory, I won’t leave any gaps. But the problem lies in the ANGLE of the teeth. Right now, they are aligned with the chip clearance slots, but they need to be slightly out of alignment with the slots. This way, when each tooth reaches its lowest point of rotation, each corner of the tooth will be at THE SAME HEIGHT. That’s the critical flaw in my current design.

I also have to give my planer some TLC…
...A few months ago, I ran a board through it that was tapered IN THICKNESS (one end was thicker than the other). Stupid me…I adjusted the planer thickness to the THIN END!!! So guess what happened when I ran the board through. It bogged down, down, down…... and I ended up snapping one of the sprockets that drive the infeed roller. Got a new sprocket in the mail, but haven’t installed it. Oh, and one of the ’’ears’’ that ride up and down on the guide posts broke off too!! Time for some J-B Weld…

So, I’m getting there. Just a lot slower than expected.
That’s life!
Thanks everyone, and keep an eye out for my further design debacles in the future!! ;-D

-- Lane Custom Guitars and Basses

View alanealane's profile

alanealane

365 posts in 2493 days


#12 posted 2029 days ago

LOL!!!
OH the PAIIIINNNN.
It’s actually red paint from the original owner of the planer. I have no idea how he spattered paint all over the machine like that, but there’s red AND white paint speckled all over the machine…a Palomino Planer!!!
Go figure…

-- Lane Custom Guitars and Basses

View BarryW's profile

BarryW

1015 posts in 2509 days


#13 posted 1972 days ago

There’s a new helical cutterhead for the Dewalt 735, I’ve read, available in Canada…but I haven’t seen it…what I’ve read is it’s expensive…very expensive…and aftermarket thing….more than the original machine.

-- /\/\/\ BarryW /\/\/\ Stay so busy you don't have time to die.

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