Grizzly G1024 User Manual

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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 REPRESENTS THE LAST CONFIGURATION OF THE MACHINE BEFORE IT WAS DISCONTIN-

UED. MACHINE CONFIGURATIONS MAY HAVE CHANGED AS PRODUCT IMPROVEMENTS WERE INCORPORATED. IF YOU OWN AN

EARLIER VERSION OF THE MACHINE, THIS MANUAL MAY NOT EXACTLY DEPICT YOUR MACHINE . CONTACT CUSTOMER SERVICE

IF YOU HAVE ANY QUESTIONS ABOUT DIFFERENCES. PREVIOUS VERSIONS ARE NOT AVAILABLE ONLINE.

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TABLE OF CONTENTS

PAGE

I. INTRODUCTION..........................................................................................................1

II. COMMENTARY ..........................................................................................................1

III. SAFETY RULES FOR ALL TOOLS............................................................................2

IV. UNPACKING................................................................................................................4

V. PIECE INVENTORY ....................................................................................................5

VI. CLEAN-UP BEFORE ASSEMBLY..............................................................................6

VII. SITE PLANNING ..........................................................................................................6

A FLOOR LOAD............................................................................................................6

B WORKING CLEARANCES ........................................................................................6

VIII. ELECTRICAL SERVICE REQUIREMENTS................................................................7

A. GENERAL ................................................................................................................7

B. GROUNDING............................................................................................................7

IX. ASSEMBLY..................................................................................................................8

A. STAND......................................................................................................................9

B. FENCE ASSEMBLY ..............................................................................................10

C. SAFETY GUARD ..................................................................................................11

X. SAFETY PROCEDURES ..........................................................................................12

XI. ADJUSTMENT SECTION..........................................................................................15

A. FENCE....................................................................................................................15

B. SPINDLES ..............................................................................................................17

C. SPINDLE ELEVATION ..........................................................................................18

D. CUTTER DIRECTION ............................................................................................18

XII. RUB COLLARS ........................................................................................................19

A. HOW RUB COLLARS ARE USED ........................................................................19

B. EXAMPLES ............................................................................................................20

C. PATTERN WORK ..................................................................................................22

XIII. SHAPING ..................................................................................................................22

A. STRAIGHT STOCK ................................................................................................22

B. IRREGULAR SHAPING ........................................................................................22

I. INTRODUCTION

We are proud to offer the Model G1024 Shaper. The Model G1024 is part of a growing Grizzly fam­ily 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 cus­tomer satisfaction.

The Model G1024 is intended for use in a home or small professional shop. This shaper features a

3

/4 H.P., 110 / 220V single phase motor and full reversing capabilities. The Model G1024 also fea-

tures a precision-ground cast iron table and

1

/2" spindle. This shaper operates at 10,000 RPM, giv-

ing you plenty of shaping flexibility at a very reasonable price.

A number of optional accessories for the Model G1024 are available through the Grizzly catalog.
They include a heavy-duty mobile base and a router bit spindle, which enable your shaper to use
most standard

1

/2" router bits.

We are also pleased to provide this instructional manual with the Model G1024 Shaper. This manu­al was written to guide you through assembly, review safety considerations and cover general oper­ating procedures. It represents our latest effort to produce the best documentation possible. If you
have any constructive criticisms or comments you feel we should include in our next printing, please
write us at the address below.

Manager, Technical Documentation

Grizzly Industrial, Inc.

P.O. Box 2069

Bellingham, WA 98227

Finally, we stand behind our machines. We have two excellent regional service departments at your
disposal, should the need arise. If you have any service questions or parts requests, please call or
write us at the appropriate location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone:[phone]

Fax:[phone]

E-Mail: [e-mail]

Web Site: http://www.grizzly.com

II. COMMENTARY

To operate this, or any power tool, safely and efficiently, it is essential to become as familiar with its
characteristics as possible. Take as much time as necessary to become acquainted with the Model
G1024 Shaper. The time you invest before you begin to use this machine will be time well spent. Also,
read all of the safety procedures. If you do not understand something, do not operate this machine.

The specifications, drawings and photographs illustrated in this manual represent the Model G1024,
as supplied when the manual was prepared. However, owing to Grizzly’s policy of continuous
improvement, changes to the Model G1024 may be made at any time with no obligation on the part
of Grizzly.

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The information in this manual has been obtained from sources believed to be reliable and as up-to­date as possible. While this manual is intended to be a substantial source of basic shaping infor­mation, it is by no means the last word on shaping. Instead, we have focused primarily on the prop­er assembly and adjustment of the machine – as well as some basic information on shaping proce­dures. We have also included some important safety measures which we believe to be essential to
this machine’s operation. While most safety measures are generally universal, Grizzly cautions that

each workshop is different and safety rules should be considered as they apply to your individual sit-

uation.

The shaper is a fundamental machine, capable of performing a wide range of work. Its primary func­tion is to profile edges for moldings and cabinets. The shaper can also be used for making joints,
grooves, flutes and profiles in many different designs and shapes.

The shaper is designed for highly-skilled individuals who have an understanding of wood and how it
mills. A strong knowledge of woodworking is essential for the proper use of the shaper and its cor­rect applications. We realize there are numerous kinds of cutters and specialized techniques used
to shape wood throughout the woodworking community. To list all of the techniques necessary to
operate a shaper correctly for specific applications would require many volumes.

If you are not familiar with shapers and their safe operation, we strongly suggest you obtain as many
books on the subject as you can. Grizzly has a number of fine books available on wood shaping. A
visit to the local library, or time spent browsing through back issues of woodworking magazines will
prove beneficial in gaining knowledge of shaper operations.

III. SAFETY RULES FOR ALL TOOLS

WARNING! As with all power tools, there is a certain amount of inherent danger associated with the

Model G1024 Shaper. Using the tool with respect and caution will considerably lessen the possibil­ity of mechanical damage or operator injury. However, if normal safety precautions are overlooked
or ignored, injury to the operator or others in the area is possible.

There are certain applications for which this tool was designed. We strongly emphasize that this tool
should never be modified and/or used for any application other than that for which it was designed.

If you are confused about any aspect of this machine, do not use it until you have resolved any

questions you might have. The following are important safety rules for all tools:

1. KNOW YOUR POWER TOOL. Read the owner’s manual carefully. Learn the tool’s applications

and limitations, as well as its particular hazards.

2. KEEP GUARDS IN PLACE and in working order.

3. GROUND ALL TOOLS. If the tool is equipped with a three-prong plug, it should be plugged into

a three-hole grounded outlet. If an adapter is used to accommodate a two-prong receptacle, the
adapter plug must be attached to a known ground. Never remove the grounding prong.

4. REMOVE ADJUSTING KEYS AND WRENCHES. Make it a habit to check that keys and adjust-

ing wrenches are removed from the machine before turning it on.

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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 WORKSHOP CHILD-PROOF with padlocks, master switches, or by removing starter

keys.

9. DO NOT FORCE TOOL. Tools work better and more safely when they are allowed to work at

their own speed.

10. USE THE RIGHT TOOL. Do not use a tool or an attachment to do a job it wasn’t intended for.

11. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, or jewelry that might

get caught in moving parts. Non-slip footwear is also recommended. Wear a hat or other pro­tective head wear if your hair is long.

12. USE SAFETY GLASSES AND EAR PROTECTION. Also use a dust mask if the cutting oper-

ation is dusty.

13. SECURE YOUR WORK. Use clamps or a fixture to hold your work. It is safer than using your

hands and frees up both hands for operating the tool.

14. DO NOT OVERREACH. Keep proper footing and balance at all times.

15. MAINTAIN TOOLS IN TOP CONDITION. Keep tools sharp and clean for best and safest per-

formance. Follow instructions for lubricating and changing accessories.

16. DISCONNECT TOOLS FROM POWER before servicing and when changing accessories, such

as blades, bits and cutters.

17. USE RECOMMENDED ACCESSORIES. Consult the current catalog for recommended acces-

sories. The use of improper accessories may be hazardous.

18. AVOID ACCIDENTAL STARTING. Make sure the switch is in the “OFF” position before plug-

ging in the cord.

19. NEVER STAND OR LEAN ON TOOL. Serious injury could occur if the tool is tipped or if the

cutting tool is accidentally contacted.

20. CHECK DAMAGED PARTS. Before further use of the tool, any part or guard that is damaged

should be promptly repaired or replaced. Do not operate the machine until you are certain it is
in perfect running condition. Failure to follow this precaution could result in further mechanical
damage and operator injury.

21. DIRECTION OF FEED. Always feed your work against the direction of blade or cutter travel.

Workpieces fed in the same direction as the cutter travel could be forced out of your control.

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-duty cardboard packaging. Carefully
remove the cardboard box by cutting through the box at its base. The top of the box can then be lift­ed off and set aside while you make your inspection of the machine. You can use the box, turned
upside down, as a receptacle for other packing materials as you prepare to set up the shaper.

If you find the machine is damaged after you’ve signed for delivery and the truck and driver are
already gone, you will need to file a freight claim with the carrier. Save the containers and all pack­ing materials for inspection by the carrier or their agent. Without the packing materials, filing a freight
claim can be difficult. If you need advice regarding this situation, please call us.

Caution: The shaper weighs a hefty 155 pounds in its packaging. DO NOT over-exert yourself while

unpacking or moving this machine. Use a heavy-duty hand truck whenever possible while moving
the shaper. If it has to be moved up or down a flight of stairs, be sure the staircase is capable of sup­porting the combined weight of you and the shaper. Always get plenty of assistance when attempt­ing to move the Model G1024.

Figure 1

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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 inven­tory. You should have the following:

• Shaper Unit

• Miter Gauge

• Spindle and Spacers

• Fence Boards

• Freehand Guard

• Bolt Bag (See below)

• Stand (4 pcs.)

• Adjustable Fence (3 pcs.)

The Model G1026 Bolt Box contains:

Rubber Feet (4)
Hex Bolt M6-1.0x12 (4)
Hex Nut M6-1.0 (4)
Flat Washer

3

/8

" (4)

Carriage Bolt M8-1.25x20 (16)

Nut M8-1.25 (16)
Flat Washer

3

/8" (16)
Slot Head Screws (4)
Flat Washer

5

/16

" (4)

Nut M8-1.25 (4)

The quantities given here are the minimum necessary to do the job; there may be some extra parts.
On the other hand, bolt bags are occasionally shipped from the factory with a nut or bolt missing.
You might consider replacing those items at your local hardware store. It’s not that we’re trying to
cheat you, but if you are short two screws that cost 10¢ apiece, it’s much cheaper to buy locally than
writing or phoning us. Even more, the time saved in shipping will mean that your shaper is ready to
use right away. Of course, if the number of items missing is extensive, or if the missing parts are
more substantial than nuts or bolts, we want to know about it, so we can eliminate problems for
future customers.

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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 careful scraping with a putty knife may be necessary where the coating is particularly
thick. Use caution when removing the coating with your putty knife to avoid scratching the table top
or painted surfaces on your shaper.

DO NOT use gasoline, lacquer thinner, acetone, or other highly-flammable solvents. The possibility

of flash fire or explosion is far greater and they don’t work much better anyway. Don’t use chlorinat­ed solvents, such as perchloroethelene; they will lift the paint and ruin the shaper’s finish. Be care­ful when working around the drive belts. Any solvent that cuts grease will, in the long run, be harm­ful to rubber. While you are cleaning the shaper, please pay attention to the following rules:

1. Work only in a well-ventilated area.

2. Make sure there are no sources of open flame in your work area, such as pilot lights or wood­stoves.

3. DO NOT smoke while you’re working.

4. Dispose of soiled towels in a proper manner to avoid fire and environmental damage.

Packaged in a separate box you will find a number of parts also covered with Cosmolene. The small­er pieces are best cleaned by placing them in a container of solvent for several minutes. After soak­ing, the remaining coating may be removed with firm pressure, using rags or paper towels. Some
pieces may have to be pried apart using a putty knife. Don’t forget to remove the fence assembly
and clean under it. Once again, dispose of waste properly.

VII. SITE PLANNING

When placing the planer in your shop, three considerations should be addressed; floor load, work­ing clearances and electrical requirements. We’ll look at the first two requirements now and leave
the third for the next section.

A. FLOOR LOAD

Your Model G1024 Shaper represents a fairly large weight load in a small footprint. For planning pur­poses, the intended work area should be able to take a uniform distributed live load of 100 pounds
per square foot. Most commercial and residential floors are suitable for the Model G1024, though
some older wooden residential floors may require some additional build up to support both machine
and operator.

B. WORKING CLEARANCES

Working clearances will vary from one customer to the next, depending on individual requirements.
Place your shaper in a position that can handle your most ambitious shaping requirements. The
working area around the shaper should be lit well enough to eliminate shadows.

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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 cord and plug. Its motor draws 10 amps. While that
is not excessive, using the Model G1024 on a circuit that is already close to capacity could result in
overload. If possible, add a circuit specifically for the shaper. A 15-amp circuit breaker is ideal for the
Model G1024.

If you choose to re-wire the Model G1024 for 220V operation, use NEMA-approved connecter plugs.
See Figure 2 for examples of typical plug configurations. You should also check with our service
department for specific information on motor re-wiring requirements. Your local building department
or a licensed electrical contractor should also be able to help you if electrical requirements exceed
your understanding.

Figure 2

If you are plugging into an existing outlet, ensure that it is grounded. If not, it will be necessary to
run a separate grounding wire, #10 copper or larger, from the frame of the machine to the ground­ing stud at your service panel.

If you find it necessary to use an extension cord with your shaper, make sure its conductors are rated
at #10 or larger (for 220V). The cord should be rated for hard service (S-type jacket), with NEMA­approved connectors and a ground wire. An SJ-rated cord (#12-wire) should be sufficient for 110V.

CAUTION: Never cut the grounding pin from the plug. If you have problems with the electrics sup-

plied with the G1024, please contact our service department for assistance. Should you decide to
use a larger motor on the machine, DO NOT rely on the information above. Contact a licensed elec­trician or your local building department for proper wiring requirements.

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B. GROUNDING

220 /240V

15A

NEMA 6-15

220 /240V

15A

NEMA 6-15

IX. ASSEMBLY

Figure 3

Carefully lift the Model G1024 Shaper from its packaging. Be sure to get plenty of help when attempt­ing 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 factory, so very little actual assembly is required. The motor is
already mounted and all wiring is in place. The remaining parts which require assembly are:

A. Stand
B. Fence
C. Safety Guard

The necessary assembly can be accomplished with a few hand tools. You’ll need a 12mm wrench,
a 14mm wrench, metric Allen wrenches and a Phillips head screwdriver. An adjustable wrench and
a metric socket set are helpful, but not essential, for assembly.

FENCE

SPINDLE LOCK

KNOB

MITER GAUGE

STAND

SAFETY GUARD

TABLE

ON/OFF SWITCH

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SPINDLE

SPINDLE

ELEVATION

HOUSING

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

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Figure 5

Once the rubber feet are connected, attach the crossbars loosely with the carriage bolts, nuts and
washers provided. See Figure 5. At this point, the stand will be somewhat wobbly. You will find it a
real help to have an assistant hold the stand in place while you attach the nuts and bolts.

When the stand’s sides and crossbars are in place, set the sheet steel top piece in place, as shown
in Figure 5. Make sure the square bolt holes are in alignment. When the bolt holes are correctly in
line, attach the remaining carriage bolts. When you’ve got all the bolts attached, tighten all the nuts
and bolts finger-tight. Working on a level surface, adjust the stand until the top piece is level. You
can verify your results by placing a carpenter’s level on the top, or measure diagonally from bottom
corner to top corner of the stand. When all of your measurements are equal, tighten all of your bolts.

After you’ve made sure the stand is level and secure, place the shaper assembly on the stand. Align
the holes on the bottom of the shaper with the holes in the top of the stand. Use the hex bolts, nuts
and washers provided to secure the shaper to the stand.

NOTE: Sheet steel will often “spring” after it has been fabricated at the factory, occasionally making
it difficult to line up precisely with other parts without a bit of effort. Don’t be surprised if the stand
requires a bit of “persuasion” to fit together. On the other hand, if the parts just don’t seem to work
together, try switching parts around (such as crossbars). If that doesn’t work, call our service depart­ment and we’ll try to help you remedy the situation.