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THE KT-16 COPY-CAT™ DUPLICATOR

GENERAL OPERATION

The WoodWrite, Ltd. KT-16 Copy-Cat™ Duplicator is a duplicating device to be used with the Model 162/363 series WoodWrite, Ltd. mini-lathes. It cannot be used on lathes in which a hand-held tool is used. The Copy-Cat uses either a metal pattern or an existing piece work. If using work turned with a hand held tool, it is best to use a 1/4" diameter mandrel, but a product turned in a chuck or using a screw center may be used as a pattern.

Since all WoodWrite, Ltd. lathes use mandrels with a zeroing point of .332" in diameter, the Copy-Cat design is based on this convenient reference point. While diameters much larger may be the end result, all measurements start at the .332 reference.

SET-UP PROCEDURE

To attach the Copy-Cat, it is necessary to remove the dust collection manifold, micrometer dial and saddle slide from your lathe. Please note the photograph below:

1. Move the saddle to the right, beyond the motor. Then remove the dust collection manifold by loosening, not removing, the two screws accessible through the vacuum hose opening in the top of the dust collection manifold. Slide the manifold back and out of the T slots.

2. Turn the micrometer handle clockwise until it will move no further, then slide the black saddle off the gold dove tailed base.

3. Loosen the 9/16" lock nut in the front of the dovetailed base attached to the micrometer dial. The micrometer dial is comprised of two pieces, the outer knob and base.

4. Unscrew the micrometer knob and the base of knob together.

5. Slide the micrometer shaft and knobs out of the gold base.

You are now ready to attach the Copy-Cat mechanism.

 ATTACHING THE COPY-CAT

GENERAL

The Copy-Cat has several parts, some of which have been pre-assembled for you. Please note photos provided as you perform each step.

1. There are two identical brackets to be mounted. Mount the first bracket as shown, closest to the head stock. Place the rounded portions over the bed rails and secure into the stationary clamp bar below the rails with the two Allen wrench screws. Do not tighten the screws, as you will be required to move this bracket later.

2. Mount the second bracket in front of the tailstock in the same way as the first.

  THE SADDLE ASSEMBLY

1. You have received a new black saddle slide, which has a blue slide attached by two adjustment screws. A new tool post is also furnished, and it is already locked in place. Slide the complete assembly onto the gold saddle. Note the small screws in the right T-slot in front of and behind the blue slide. Move the blue slide back to expose the front screw. Tighten it with a 3/32 Allen wrench. Now slide the blue slide forward to expose the rear screw and tighten it. Also tighten the 3/32 screw(s) on the right side of the black saddle slide. The black saddle slide should be tightly secured to the gold saddle. It should not move, but the blue slide should move back and forth easily.

2. The next step is to assemble the stop assembly, which consists of an almost square plate, into which are drilled several holes. At the bottom of the assembly are two holes matching the two tapped holes in the gold saddle base. Assemble this part to the gold saddle with the notch to the right. The black headed depth adjuster with wing nut is on the left. Note the position of the washers in relation to the head of the screw and bottom of the spring.

3. Insert the shoulder screw and spring into the center hole of the 8/32 screw hole in the center of the blue slide. Use a flat head screwdriver or Allen wrench, depending upon the screw provided, to tighten securely.

At this stage, your assembly should appear as noted below:

THE PATTERN FOLLOWER

1. The pattern follower comes completely assembled. Place it on top of the slide and screw it onto place with the 3/4" Allen wrench screws provided.

2. Assembly is now complete with the exception of the attachment of the pattern.

THE PATTERN

One blank pattern (for making your own template, or for turning straight barrels such as Slimline), and two additional patterns are furnished with your Copy-Cat. One pattern is for Continental (Mont-Blanc style) pens, and the other is WoodWrite, Ltd.’s "Gibson Girl" template for use with Slimline pen or pencil components and our SuperSlim wood blanks.

1. Mount the pattern between the two brackets you originally mounted on the lathe. The short etched line on the pattern should be on the left. With the cut portion of the pattern away from you, slide the pattern onto the brackets, making sure that the washers are on top of the pattern. Fasten lightly in place with the two 10-32 Allen wrench screws already in place on the brackets. You may have to adjust the position of the brackets to insure a correct fit. Tighten the brackets, but do not tighten the pattern screws yet.

2. Align the pattern follower with the pattern by moving the saddle assembly toward the head stock until the tool is located in the calibration area of the mandrel. See photo below:

You may find it necessary to push back on the slide assembly to prevent the tool from touching the mandrel. Turn in on the black Depth Adjuster screw to push the tool away from the mandrel. Whenever using the Depth Adjuster Screw, it is important to finger-tighten the wing nut to prevent vibration from moving the screw during operation.

3. With the tool placed in the calibration area, turn the black Depth Adjuster screw until the tool just touches the mandrel. Now, turn the stop screw (Allen screw with nut), until it touches the slide assembly. Holding the screw in place with an Allen wrench, tighten the locking nut against the guide plate. This screw is used to prevent the slide from advancing forward and cutting into the mandrel. During this adjustment, the black Depth Adjuster screw should not touch the slide.

4. Move the pattern toward the mandrel, until it just touches the pattern follower in the flat (calibration) area of the pattern.. Tighten the left pattern screw.

5. Move the saddle to the right until the pattern follower reaches the flat area on the opposite end of the pattern. Adjust the pattern once again to allow the pattern to just touch the pattern follower. You may need to repeat steps 4 and 5 to ensure the opposite ends of the pattern just touch the pattern follower.

6. Move the tool so that the tip is just to the left of the wood to be cut. Loosen the two bracket clamps and slide the bracket assembly along the rails until the follower is just to the left of the etched line. See photo on following page:

7. Assemble your dust collector manifold on the Copy-Cat. Notice that this new and improved manifold has the hose entering from the top, rather than the back. The hose should be supported and curve up and down into the manifold. No weight should be on the saddle assembly. Failure to properly support the hose assembly will prevent the Copy-Cat from following the pattern. We find that it is best to drill a hole in your bench behind the lathe, snake the hose up through this hole, and down to the manifold. Alternatively, you may bring the hose to the manifold from above your workbench.

Assembly of the Copy-Cat is now complete.

Completely assembled Copy-Cat showing hose entering Dust Collection Manifold at top.

OPERATING THE COPY-CAT

With your micrometer dial disconnected, the depth of cut is easily controlled by the black Depth Adjuster screw in the guide plate. Move the saddle so that the tool is to the left of your wood blanks. Adjust the screw with the black knob so as to make a cut not exceeding 1/16" deep (remember to finger-tighten the wing nut). It is always better to take off too little than too much. Keep in mind that the Copy-Cat is spring loaded and therefore does not allow as deep a cut as a tool mounted normally with the micrometer. Experimentation will allow you to determine the optimum depth of cut, but PLEASE DO NOT ATTEMPT DEEP CUTS. Now turn on your lathe and make the first pass.

1. After your first cut, you will probably notice that the follower has not yet touched the pattern. Turn the Depth Adjuster screw one turn counter-clockwise. Make your second cut.

2. Continue making cuts right and left. As the follower reaches the pattern, the work will begin to take the shape of the template.

3. When the follower reaches the depth of the calibration point, you have completed cutting. The last few cuts will be at the ends of the pattern. Sand and polish your work with Turner’s Magic and assemble your pen/pencil.

QUESTIONS & ANSWERS

Q. When I completed my pen, I noticed that it was a little too large in diameter. How do I adjust the Copy-Cat?

A. When you set the calibration point, the locked screw may not have been touching the blue slide portion. Readjust the calibration point. Remember, you must remove the dust collector to get to the proper point on the mandrel. If your calibration was proper, you can increase or decrease the diameter of your finished product by adjusting your template. Moving the template toward the lathe will increase the diameter, and moving the template away from the lathe will decrease the diameter.

Q. When I completed my pen, it was too small in diameter. How do I compensate?

A. Reset the calibration of your tool. (See above answer.)

Q. Can I make standard straight barrel pens without disconnecting the Copy-Cat?

A. Yes, you can make straight barrel Slimline pens or pencils using the straight sided "blank" pattern.

Q. I seem to have chatter when cutting the wood. What’s wrong?

A. You may need to tighten the spring loaded screws in each edge of the slide, or you might be a bit too aggressive with your depth of cut. Don’t back out the black Depth Adjuster screw so far.

Be aware that if you tighten the spring loaded screw too tight, the blue slide will bind and not move. Easy does it!

Q. I’m really confused. How do I obtain technical support?

A. That’s the easiest answer of all! Call Jack or Phil at WoodWrite, Ltd. (888-966-3974) and we’ll walk you through. Don’t give up! We’re as near as your phone.