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The KT-19 Copy-Cat™ Duplicator

GENERAL OPERATION

The WoodWrite,Ltd. KT-19 Copy-Cat™ Duplicator is a duplicating device to be used with the Model 60 series WoodWrite,Ltd. mini-lathes. It also is compatible with mini lathes by Taig and Penn State Industries. 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 as a pattern work which has been turned with a hand held tool, it is best to use a 1/4" diameter mandrel, but a product turned using a chuck or 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 to your WoodWrite,Ltd. Model 60 series mini-lathe, first loosen and remove the tailstock from the lathe bed. Next, remove the entire saddle assembly by turning the saddle movement knob clockwise until the entire saddle mechanism slides off the bed. When the pinion disengages from the rack mechanism, it will be necessary to gently push the saddle to the right so that it will slide off the bed. You are now ready to put the Copy-Cat™ mechanism on the lathe bed.

 You have been furnished with the following pieces:

1. A left hand pattern holding bracket stamped "L"

2. A right hand pattern holding bracket stamped "R"

3. A complete, new saddle assembly, pre-assembled.

4. An E-Z Glide™ spoked knob.

5. Three patterns for use with the Copy-Cat. They are:

a) One MontBlanc® style pattern stamped "MB" (use WoodWrite,Ltd.’s Continental™ pen mechanicals)

b) One Gibson Girl pattern stamped "GG" (use Slimline pen mechanicals and SuperSlim wood blanks)

c) One blank pattern for straight pieces or to make your own cured pattern.

ASSEMBLY INSTRUCTIONS

First, slide the bracket marked "L" onto the lathe bed. The clamping bar should be placed at the rear of the bed. Slide this bar all the way up to the head stock and tighten the allen wrench screw with the 5/32" allen wrench.

Second, slide the new assembly onto the lathe bed. Insert the EZ-Glide™ knob into the hole at the base of the saddle and carefully turn it counter-clockwise until the pinion engages the rack. Next, move the saddle until it is in the middle of the lathe bed. Rock the saddle right and left to check for looseness. If the saddle rocks, it may be necessary to adjust the two set screws in the rear of the saddle. Loosen the two 5/16" nuts and adjust the set screws until all play is taken out of the saddle. Remember, however, that this assembly must slide easily on the lathe bed when the E-Z Glide™ knob is turned. Tighten the set screws only enough to eliminate any rocking of the saddle. It is better to have the saddle too loose than too tight. After adjusting the two set screws, hold the screws with the 3/32" allen wrench and then lock them each in place with a 5/16" wrench on the nuts.

Now, slide the bracket marked "R" onto the lathe bed and replace the tailstock. If you have followed the above instructions correctly, your lathe should now look like the picture below.

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 bracket should be on the left. With the cut portion of the pattern away from you, slide the pattern onto the brackets. The washers should be placed one under and one over the pattern. Fasten lightly in place with the two 8-32 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 photos 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. Tighten the left pattern screw.

5. Move the saddle to the right until the pattern follower reaches 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. There is a short etched line in the pattern on the left side. Move the tool so that the tip is just at the beginning of the work to be turned. Loosen the two bracket clamps and slide the bracket assembly along the bed until the follower is to the left of this line.

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. Alternately, you may suspend the hose from above, down to the manifold.

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