magic molder - magic molder (Rating: 5)

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The Magic Molder System consists of a molder head and cutter plugs. Although not inexpensive, Magic Molder constitutes a truly safe and professional system for using your table saw (or radial arm saw if so inclined) as a shaper for cutting molding profiles. There are three primary features that make this system head and shoulders above the previous molder head I acquired 30 plus years ago-one I'll humorously describe as a "cubby, Ninja star."

First, the Magic Molder is the safest design I've seen for a table saw molder system. The head has two, approximate 1-3/4" circular openings 180 degrees apart, the bottoms being about 1-3/16" below the outer circumference of the head so that the plug's diameter is well below the surface. This encloses and surrounds the plug so it can't be thrown out from the head. The round cutter plugs come in some 83 different profiles. These cutter plugs are locked into the head by first sliding the plug into the head and then twisting the plug to lock it in place. (This locking groove can be seen in the second photograph above.) The plug is then set in the locked position by tightening the setscrew that is on the opposite side of the locking groove. (See the third photograph above.) The old system I have, like all the other molding head systems that I'm familiar, has flat profile blades that are locked into a slot on the head. Also, the old molding head appears to have been made out of a pot metal that always seemed to flex when the locking, hex screw was tightened. The Magic Molder head has no flex and locks solid.

Second, the Magic Molder head is machined from top quality aluminum and the cutter plugs are machined from steel. The quality and precision is obvious from the photographs and a physical examination only confirms the beauty of these machined parts. The balance is perfect, creating a sweet hum when the saw is turned on. As noted the head has no flex when the plugs are tightened and the treads are cut in aluminum so there is no concern that such threads will strip when tightened. These 7" diameter heads are available with 5/8", 3/4" or 1" bores. The plugs are electronically balanced to make them vibration free.

Third, the profile cutters are carbide instead of HSS. The plug cutters are set in the head in an anti-kickback profile that produces a smooth, vibration-free cut due to this chip limiting design. I can attest that the cuts are chip free as can been seen from these molding cuts I just completed on highly figured white oak:



Fifteen years ago, I built a Norm Abrams Delft Rack in Mahoney to match a buffet I inherited from my great aunt. This project presented great challenges for cutting molding to complete the requisite trim. I'm working on a rebuild of this Delft Rack in white oak as a gift for family and friends. I'm thinking that I'll blog my experiences using this Magic Molder system to cut these moldings just for the fun of blogging and using my new Magic Molder head and plugs.

P.S. I first learned about the Magic Molder from my buddies at Ballew Saw & Tool here in Springfield, MO (325 S. Kimbrough Ave., 417-865-7511), and also learned they now own the patent and trademark, as well as sell the head and cutter plugs. You can learn more from the following link if interested:

P.P.S. Please see the project post of my Auxiliary TS/Router Fence and FB Rail at http://lumberjocks.com/projects/106533 to see my answer to how I safely use the Magic Molder to cut molding; and, my product review of the Grip-Tite Magnetic FB for holding stock on the joiner, http://lumberjocks.com/reviews/4029