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Table of contents for the manual
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- 1 - IMPORTS, INC. 3 / 4 H.P. SHAPER MODEL G1024 INSTRUCTION MANUAL COPYRIGHT © 1994 BY GRIZZLY INDUSTRIAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. REVISED JUNE, 1994. PRINTED IN USA DISCONTINUED MACHINE MANUAL DISCLAIMER THE INFORMATION IN THIS MANUAL[...]
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- 2 - TABLE OF CONTENTS PAGE I. INTRODUCTION ..........................................................................................................1 II. COMMENTARY ..........................................................................................................1 III. SAFETY RULES FOR ALL TOOLS ..........................................[...]
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I. INTRODUCTION We are proud to offer the Model G1024 Shaper. The Model G1024 is part of a growing Grizzly fam- ily of fine woodworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly’s commitment to cus- tomer satisfaction. The Model G1024 i[...]
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The information in this manual has been obtained from sources believed to be reliable and as up-to- date as possible. While this manual is intended to be a substantial source of basic shaping infor- mation, it is by no means the last word on shaping. Instead, we have focused primarily on the prop- er assembly and adjustment of the machine – as we[...]
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- 5 - 5. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. 6. AVOID DANGEROUS ENVIRONMENTS. Do not use power tools in damp or wet locations or expose them to rain. Keep your work area well lighted. 7. KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept a safe dis- tance away from your work area. 8. MAKE WORKS[...]
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22. NEVER LEAVE THE TOOL RUNNING UNATTENDED - TURN POWER OFF. Do not leave the tool until it comes to a full stop. 23. DRUGS, ALCOHOL, MEDICATION. Do not operate the tool under the influence of drugs, alco- hol, or any medication. Never operate machinery when overly fatigued. IV. UNPACKING The Model G1024 Shaper is shipped from the factory in heavy[...]
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V. PIECE INVENTORY Take a quick inventory of the parts and put them aside for assembly later. Since the majority of the shaper is pre-assembled at the factory, there aren’t a lot of items to inven- tory. You should have the following: • Shaper Unit • Miter Gauge • Spindle and Spacers • Fence Boards • Freehand Guard • Bolt Bag (See bel[...]
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VI. CLEAN-UP BEFORE ASSEMBLY All of the unpainted surfaces on this machine – and a few of the painted ones – are coated with a preservative oil, called Cosmolene, which prevents rust and corrosion during shipping. The coating can be removed with paint thinner (mineral spirits) and a good supply of paper towels, although you may find that carefu[...]
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VIII. ELECTRICAL SERVICE REQUIREMENTS The Grizzly Model G1024 Shaper is furnished with a complete electrical package: A 3450 RPM TEFC 3 / 4 H.P. motor, ON-OFF starter switch, FORWARD/REVERSE switch and a cord set. The motor is single phase and may be operated on 220/240V, as well as 110/120V. A. GENERAL The Model G1024 comes with a standard 110V co[...]
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IX. ASSEMBLY Figure 3 Carefully lift the Model G1024 Shaper from its packaging. Be sure to get plenty of help when attempt- ing to lift or move the machine. The Model G1024 Shaper has a shipping weight of more than 150 lbs. Make sure you have plenty of help when it comes time to move the machine. The Model G1024 is largely pre-assembled at the fact[...]
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A. STAND The Model G1024 Shaper features an A-frame stand. Begin assembling the stand by attaching the four rubber feet to the bottom of the side panels with the M6-1.0x12 hex bolts, M6-1.0 hex nuts and 3 / 8 " flat washers provided. See Figure 4. Figure 4 - 9 - Figure 5 Once the rubber feet are connected, attach the crossbars loosely with the[...]
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- 10 - B. FENCE ASSEMBLY The Model G1024 Shaper comes with a two-piece adjustable fence. Before attaching the fence unit to the shaper table, you will want to “wood” it. The wood fence pieces included with the Model G1024 are pre-drilled and counterbored to allow the slotted mounting screws to rest below the wood surface once they are tightened[...]
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C. SAFETY GUARD The Model G1024 features a clear acrylic safety guard which is designed to deflect wood chips away from the machine’s operator. To attach the guard, slip the support rod into the hole provided in the bracket bolted to the back of the shaper table. See Figure 7. The height of the safety guard can be adjusted by loosening the lockin[...]
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X. SAFETY PROCEDURES This tool is capable of causing serious injury if used recklessly. This doesn’t mean that the machin- ery should be feared, but it does deserve a healthy respect for its power and potential danger. At the beginning of this manual we shared some general safety procedures with you. We want to re- emphasize a few points we feel [...]
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14. HAND SAFETY. Never pass your hands directly over, or in front of the cutter. As one hand approaches the 12-inch radius point, move it away from the cutter to the outfeed side and repo- sition the hand at least 12 inches beyond the cutter. 15. STOCK FEED. Always feed stock opposite the direction of the cutter rotation. For example, if the cutter[...]
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20. STOCK CONDITION. The danger of experiencing kick-back is increased when the stock has knots, holes, or foreign objects in it. Warped stock should be run through a jointer before attempting to run it through a shaper. 21. MISUSE. Do not use the Model G1024 for anything other than its intended purpose. If used for other purposes, Grizzly disclaim[...]
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XI. ADJUSTMENT SECTION Any adjustments or maintenance performed on the Model G1024 should be done with the power off, the plug disconnected from the power source and only after all moving parts have come to a com- plete stop. Make sure the machine is level and secure. The following are recommended steps for adjusting the shaper. Please read the fol[...]
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- 16 - Outfeed Fence Cutter Rotation Workpiece Infeed Fence Feed Direction Improper Fence Adjustment Figure 11 When the shaping operation removes the entire face of the workpiece, the shaped surface will not be supported by the outfeed fence when the fences are paralleled, or mis-aligned, as shown in Figure 11. In this case, a test sample of the de[...]
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- 17 - C U T T E R Feed Direction Workpiece Cutter Rotation Outfeed Fence Infeed Fence Figure 13 Take your time when adjusting the fence. Always use a piece of scrap wood to make a first run sam- ple. Micro-adjust accordingly. Double check yourself to make sure all hold-down devices are secure. Remember to use appropriate guards when using the fenc[...]
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C. SPINDLE ELEVATION The Model G1024 Shaper features a locking spindle which can be adjusted for up to 7 / 8 " of vertical movement. To adjust the height of the spindle: 1. Loosen the locking knob on the right-hand side of the shaper. 2. Reaching under the shaper table, move the vertical adjustment lever right or left until the spin- dle reach[...]
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- 21 - XII. RUB COLLARS Rub collars are used when shaping curved or irregular workpieces, such as arched doors or round table tops. They also allow you to perform freehand work. There are two types of rub collars; solid and ball-bearing. Don’t confuse spacers with solid rub col- lars. Spacers aren’t always machined to close tolerances and not e[...]
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B. EXAMPLES Rub collars may be used in any of the following positions: 1. Below the cutter. 2. Above the cutter. 3. Between two cutters. Suppose you want to mill a 3 / 8 " x 1 / 2 " rabbet. You must have a sufficient amount of uncut wood to provide adequate contact with the rub collar. Remember that the width of the rabbet is controlled b[...]
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Spindle Assembly Table Table Rub Collar Spindle Nut Workpiece Cutter Figure 18 When the collar is used above the cutter, as shown in Figure 18, the cut cannot be seen. Yet, this offers some advantage in that the cut is not affected by slight variations in the stock. Also, accidental lifting will not damage the workpiece. Simply correct the mistake [...]
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C. PATTERN WORK When using a pattern, the rub collar can be positioned either above, below, or in-between cutters. See Figure 20. The pattern is usually used when the entire edge is to be shaped or when many duplicate pieces are needed. Pattern work is particularly useful when rough cutting irregular shapes oversize and then shaping the edge in a s[...]
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5. Position the fences for your desired depth of cut. See the fence adjustment section for details. 6. Use a hold-down, or other safety device. See Figures 21 and 22. 7. Make a sample cut on a scrap piece of wood to check your adjustments. 8. If everything is correct, run your stock through the shaper using your left hand to support the workpiece a[...]
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B. IRREGULAR SHAPING Irregular or freehand shaping takes a high degree of skill and dexterity. This is where the real appli- cation of the shaper comes into focus. The fence assembly is not used in irregular shaping, so rub collars must be used. Choose the correct diameter for the appropriate depth of cut. See the rub col- lar section for details. [...]
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5. Insert a starting pin into the table surface, using the pin location that best supports your work. 6. Inspect your stock or pattern for any irregularities that might transfer to the cut. 7. Use some type of hold-down fixture and guard when doing freehand work. See Figure 24. Figure 24 8. Make a sample cut on a piece of scrap wood. 9. If everythi[...]
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Figure 25 When making a pattern, jig, or fixture, here are a few things to consider: 1. Use a material that will smoothly follow the rub collar or fence. 2. Make the fixture stable. Use proven methods and materials. 3. Fasten hand holds for operator comfort and safety. 4. Secure your workpiece on three sides with toggle clamps or fasten the workpie[...]
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XIV. EQUIPMENT MAINTENANCE Your Model G1024 Shaper requires very little maintenance. A thorough cleaning, now and again, will increase the machine’s durability and efficiency, by removing dust and grime that can gum up mov- ing parts. Sharp cutting surfaces are essential for top performance. If you find that the machine cuts less efficiently than[...]
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XVI. MACHINE DATA GRIZZLY MODEL G1024 3 / 4 H.P. SHAPER Design Type ....................................................................................................................Floor Model Overall Dimensions: Table .......................................................................................................................... .....[...]
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XVII. WARRANTY AND RETURNS LIMITED WARRANTY Grizzly Industrial, Inc. warrants every product it sells for a period of one year on all parts and one year on all electric motors to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alt[...]
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- 32 - XVIII. PARTS LISTS AND DIAGRAMS A. MAIN BODY ASSEMBLY 8 10 109 110 9 107 108 7 1 2 3 4 5 6 113 11 114 12 18 15 13 16 20 23 106 105 19 14 17 21 22 104 97 98 99 112 100 101 102 103 95 94 92 91 82 81 111 80 78 79 77 76 75 74 66 72 73 70 71 69 68 65 67 58 57 63-1 63 45 43 42 48 49 46 44 34 29 28 40 39 38 37 36 35 31 32 33 25 26 24 27 64 56 53 52[...]
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- 33 - 001 P1022003 Side Panel 002 P1024002 Tie Bar 003 PB02M Hex Bolt M6-1.0x12 004 P1024004 Rubber Foot 005 PW02 Flat Washer 3 / 8 " 006 PN01M Hex Nut M6-1.0 007 PW02 Flat Washer 3 / 8 " 008 PN03M Hex Nut M8-1.25 009 PCB01M Carriage Bolt M8-1.25x20 010 P1024010 Shelf 011 PN03M Hex Nut M8-1.25 012 PW02 Flat Washer 3 / 8 " 013 PB06M [...]
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- 34 - 075 P1026223 Safety Washer 076 P1024076 Cutter Spindle 077 P1024077 Bearing Cover 078 P1024078 Spindle Cartridge 079 P1024079 Steel Ball 080 PR23M Retaining Ring 40mm 081 P6203 Ball Bearing 082 P1024082 Spindle Housing 083 P1024083 Bearing Cone 084 P1024084 Coil Spring 085 PSS20M Setscrew M8-1.25x8 086 P1024086 Spring Collar 087 P1024087 Stu[...]
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XIX. USING THE MODEL G1793 ROUTER BIT SPINDLE - 35 - The Model G1793 Router Bit Spindle is a handy accessory available for your Model G1024 shaper, which allows you to use your standard router bits as shaper cutters. Using the optional router bit spindle does require some minor modifications to the Model G1024. To maximize the effectiveness of the [...]