WILLIAMS & HUSSEY MACHINE CO INC
MODEL 206 MOLDER
OPERATOR’S MANUAL
MANUAL NUMBER OM-99
ADDRESS; 70 Powers St, Milford NH 03055
info@williamsnhussey.com www.williamsnhussey.com
1800 258 1380 603 732 0219 fax 603 732 4048
Customer Service is available Monday-Friday, 8:30 AM- 4:30 PM EST
JULY 2010
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SPECIFICATIONS ACCESSORIES
MOTOR 2HP ELLIPTICAL JIG EJ-92
RPM 6900
FEED RATE 0-19FPM CRANK EXTENSION 54-306
MAX PROFILE DEPTH ¾”
MAX PROFILE WIDTH 6 ¾”
PLANING WIDTH 7”
MIN STOCK LENGTH 9”
MIN STOCK THICKNESS ¼”
MAX STOCK THICKNESS 8”
WORKING HEIGHT 35”
OVERALL HEIGHT 50”
OVERALL WIDTH 22”
OVERALL LENGTH 28”
BOXED WEIGHT 218#
SAFETY RULES
Your W&H Molder has been designed for maximum safety, however, as with all power tools; there is a
possibility of incident or injury to the operator. Therefore, it is imperative that this manual is completely read
and understood before using.
Use your W&H Molder with respect and caution. Following stated and inherent safety precautions will
considerably lessen the possibility of personal injury. If normal safety measures are not taken or are overlooked,
the possibility of incident rises tremendously. These safety measures are simple to follow, and the injuries that
could happen are not worth the few minutes saved by ignoring safety.
The W&H Molder was designed for specific applications. Do not modify or use the machine for any purpose
other than what this manual describes as its capabilities. Substituting a motor with a horsepower rating over
2HP constitutes a modification. Any modifications or improper use to the Molder-Planer may result in personal
injury, and will void the warranty. Please contact us if you are unsure about safety protocol before using the
machine.
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SAFETY CHECK LIST DON’T TAKE UNNECESSARY RISKS!
Failure to read and apply manual instructions will cause poor performance, unnecessary repairs and
injury.
Wear safety glasses and use respiratory protection.
Disconnect the power before servicing or changing knives.
Wear footwear that does not slip. This will help you keep proper footing and balance. Always stand beside the
machine, never in the way of the in-feed and out-feed areas.
Keep knives sharp and clean.
Make sure the machine has proper grounding.
Make sure all guards are secured and in working order.
Remove all adjusting keys and wrenches before starting.
Check the stock for loose knots, nails, and foreign matter.
Keep the machine in a dry, clean, and well-lit area.
PREPARING TO USE THE MACHINE
1. Disconnect the power source while going through these procedures.
2. Check knives to ensure that the bolts are tight. If molding, set your guides for the stock path through the
knife area. If planing, you may or may not wish to set your guides. Many times, they are not needed in
planing.
3. When molding, the head scale setting must be set to within 3/16” of the height of your stock. The “0” on
your scale is set to the top of your GS-2 guide system sub-plate. This means you would set the machine
head reference to the scale at ¾” in order to take a full profile pass on a ¾” piece of stock. You could set
the machine head in reference to the scale at 15/16” for a maximum height first pass (3/4” + 3/16”). This
setting will provide the proper roller tension. Any other setting higher from the thickness of the stock
entering the machine is unacceptable and dangerous. See the molding section for more information.
4. The chip extractor loads first under the out-feed end of the head with a lip under the cast head. You then
finish by attaching the chip extractor with its pin. Make sure the pin is inserted all the way in until you
feel it “catch” on the spring-loaded catch.
5. Check rotational clearance of the knife with the chip extractor in place. Rotate the knife by hand at the
5” pulley cut out on the inner belt guard to ensure the knife area is clear.
6. Do not stand or let others stand in the out-feed area or directly in line with the in-feed of the machine.
7. With the head set in the proper position, tighten the head locking bolt firmly. This is essential for safety
and to ensure the machine head will stay where you have set it.
8. Test a piece of stock, with the machine off, to see if it will make contact with the in-feed roller.
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VARI-FEED OPERATIONAL TIPS
The main control start button starts the knife motor and the Vari Feed motor. The speed control knob controls
the speed of the feed rollers.
The stock feed rate is approximately from 0 to 19 fpm (feet per minute), depending on where the knob is set.
Higher rates of feed are only recommended for lighter depths of cuts. Turn the knob clockwise to increase the
feed rate.
When the dial is in the 9 o’clock position the feed speed is approximately 4 fpm.
At the 12 o’clock position = approximately 6 fpm
At the 3 o’clock position = approximately 14 fpm
At the full to the right position = approximately 19 fpm
Always remember to set your stock rate prior to entering the stock into the machine. The feed rate may be
changed during the cut.
The vari-feed option allows for high feed rates on relief cuts on the backside of casings. The vari-feed multipass combination provides the versatility of slow feed rates on deep hardwood profiles making possible two or
three passes to finish.
On deep and wide profiles you can now raise the knife for a partial profile cut and enter the stock very slowly,
while engaging the butt into the knife gently, letting stock move under the out-feed roller before engaging a
higher feed rate. This reduces the incidence of a large chip out, a chatter mark or snipe on the first few inches
of your stock. You have the same advantages exiting the cut.
As the grain structure changes throughout the cut you can vary the stock feed rate to reduce the possibility of
chip outs and spoilage of your piece of stock.
Before starting the machine first familiarize yourself with the rest of this “Owners Manual”. It is very important
to safely operate the machine as outlined in this “Owners Manual”. Operate the machine only within the
described design intent.
Be sure you check for rotation direction before you use the machine. See the rotation illustration in the changing
knives section.
MOTOR LOCK
Your newly designed machine base has a motor lock. This new devise allows you to lock your motor in place to
keep it from bouncing on the belt during interrupted cuts etc. It also allows you to modify the belt tension which
can aid you in achieving the finish quality you are looking for.
To reduce tension you can crank the head down to within 1/4” of the actual setting you will use and lock your
motor. Then reset your head to the 1/4” lower running position and your tension will be reduced. You can vary
the 1/4” factor to achieve the tension you desire.
Always unlock the motor before resetting the machine head height.
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CHANGING KNIVES DISCONNECT POWER BEFORE CHANGING KNIVES!
KNIFE
ARBOR
KNIFE BEVEL
INFEED SIDE
OUT-FEED SIDE
VIEW FROM PULLEY SIDE OF MACHINE
ROTATION
PLANER KNIVES
CAUTION; when planing always back off all four pressure screws to a position ¼” higher than the fully seated
position.You will create too much roller pressure and feeder problems if you don’t.
Remove the chip extractor by pulling out the pin and lifting the infeed end up first and pulling it back to clear
the lips hold. Clean off knives and machine arbor. Set one knife at a time in place against the lip of the arbor.
Place the “bevel” of the knife as shown in the illustration below. Tighten the eight bolts securely using a 7/32”
allen wrench. After tightening, double check to see that the knives are snug against the lip.
MOLDING KNIVES
Clean off knives and machine arbor. Set one knife at a time in place with
the bevel edge positioned as shown in the illustration below. Push the
knife firmly down against the arbor lip and sideways against the bolts in
the direction of the tube side of the machine. Hold secure while tightening
the bolts.
KNIFE SHARPENING
For fast and professional results with minimum edge loss, return your knives to the factory for re-sharpening.
Have your knives re-sharpened when you first notice some dullness. This gives optimal performance and
maximum life span out of the knives.
Molding knives should be surface ground on the face in pairs or the profiles should be
reground. Sometimes it is better to regrind the profile. If you send them to us for
regrinding we will use the best method that will prolong the use of your knives.
Planing knives may be ground on the surface or on the bevel.
Both molding and planing knives have an edge angle of 57 degrees measured off the
back of the knife.
Face of knife
Hook angle is 11 degrees
The use of dull knives will put a strain on the feed mechanism and will result in your need of a repair. Any
problems created due to the use of dull knives are not covered under the warranty.
HOW TO MOLD
You will normally use the guide sub-plate. When using the optional jig you will take it off. Always use your
sub-plate on any job where the knife is designed to cut below the bottom of the stock. This type of knife will hit
the base of the machine if a sub-plate is not used. An example of this situation would be the moulding of half or
quarter rounds.
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The “0” on your head setting scale references the top of the ½” sub-plate supplied with your machine. For
example if you were milling a ¾” piece of stock you would set the machine head at the ¾” setting. Adjusting
your machine head to this scale setting will give you a full pass cut and a completely finished profile. This is a
multi-pass machine and with multi-pass you can add 3/16”, in this example, to the 3/4” dimension for a first
pass setting of 15/16”. In this example you may set the machine head to any scale setting between 3/4” and
15/16” for a first pass. These settings allow you to achieve proper roller tension for holding the stock and
providing a safe operation.
Be sure to check for sufficient feed roller contact before proceeding to use this setup and be sure to rotate
your moulding knives to check for knife rotation clearance with the chip extractor installed and the power
off before starting the machine. Turn the knife arbor by turning the motor pulley at the inner guard opening.
Other moulding tips
Stock height should be within 3/16” of finished moulding size. If making one pass only it should be within
1/32”.
Stock width should be uniform and to finished moulding size. Saw ripping to width will not make the stock
uniform enough for smooth flow through the guides, and thus, will not result in a satisfactory molding. We
recommend that all stock be planed in both width and height to finished moulding size before setting up to do
the profile.
When tightening the knives, push them firmly against the lip and sideways against the bolts in the direction of
the tube side of the machine for an exact profile match up. Hold secure while tightening bolts.
Set the head height to within 3/16”of your stock height. This will give you proper roller tension on your
moulding stock. This is the correct way to mold. It is acceptable to leave 3/16” of the cut for multiple passes.
But for safety reasons leave no more than 3/16”.
On some extremely deep or wide cuts, some prior stock removal will be required before molding. You may
remove this stock using one of the rabbet/dado knives found in our catalog. You may also use a dado blade on a
table saw.
Failure to set your head height within 3/16” of the stock height will create an extreme safety hazard in that
possibly not enough roller pressure will be applied, or that no roller pressure at all will be applied.
Do not cut a wider stock area than the knife was designed to cut. This will cause excessive heat in the knife,
burn your stock and puts a harmful load on the feed system.
The roll pressure screws are set at maximum molding pressure from the factory. They are screwed into the head
as far as possible and the check nut is tightened.
When you use the machine for planing you will need to reduce the roller pressure. Loosen the pressure screw
lock nut and screw out each pressure to a setting ¼” higher than the fully seated position and retighten the lock
nut.
To change the molding knives, remove the chip extractor. Set one knife at a time in place with the bevel edge
toward the in-feed end of the machine. Firmly push the knife down against the arbor lip and sideways against
the bolts in the direction of the tube side of the machine. Hold secure while tightening bolts with a 7/32” allen
wrench or drive.
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