FLETCHER Fillet Chopper For Framed Art Pieces Owner’s Manual

: September 13, 2024
: FLETCHER

Table of Contents

FLETCHER Fillet Chopper For Framed Art Pieces
SAFETY FIRST
Assembly and Mounting
10 nuts and washers from the right side of the cutter base. Position the
10 washers and nuts. Tighten the nuts while keeping the two ends of the
Operation
Spare Parts
SPARE PARTS
PRODUCT WARRANTY
CONTACT INFORMATION
Read User Manual Online (PDF format)
Download This Manual (PDF format)

FLETCHER Fillet Chopper For Framed Art Pieces

Introduction

Thank you for purchasing the Fletcher Fillet Chopper, our new product developed in collaboration with Frame Square Industries. You have chosen a tool that will give you the precision and quality you need to build your business—whatever its size. This new fillet chopper will handle fillets & lip liners up to 1-1/2” wide and features an indexing fence for nibbling the wider materials. The Fletcher Fillet Chopper is built with a high mechanical advantage. Its heavy-duty construction is used throughout the machine for a longer life. For a complete fillet measuring and cutting system, the Fletcher Fillet Chopper works best with the Fillet Master™ from Fletcher-Terry. For maximum safety and productivity, please read and understand this manual thoroughly before you operate your new Fletcher Fillet Chopper.

SAFETY FIRST

Please read through this manual before operating the Fletcher Fillet Chopper. If after reviewing these pages you still have questions about using the machine, contact our Customer Service Department toll-free at 1.800.843.3826 (in the U.S.) or 860.677.7331 (outside the U.S.) You can also email us at customerservice@fletcher-terry.com.

It is the employer’s responsibility to enforce compliance with these safety warnings and procedures by all who use the Fletcher Fillet Chopper. Keep this manual available so all employees have access to it and have the opportunity to review procedures periodically.
The intended purpose of the Fletcher Fillet Chopper is to cut fillets for use in custom frames. It must not be modified or used for any other application or purpose.
The Fletcher Fillet Chopper is for use in cutting wood and plastic materials, not aluminum or any other metal. Do not attempt to cut metal with the Fletcher Fillet Chopper.
Use safety glasses. The operator of this machine, and others in the work area, must wear safety glasses with rigid side shields.
Only use the parts, supplies, and accessories that are recommended by Fletcher-Terry.
Do not over-reach or use the Fletcher Fillet Chopper from an awkward or insecure position. Make sure that the work area is well-lit, free from clutter, and set up in a way that promotes proper ergonomics.
Use care when cleaning under or around the Fillet Chopper. THE BLADES ARE VERY SHARP, AND THE GUARDS CAN PROTECT YOUR FINGERS IF YOU REACH AROUND THEM OR UNDER THE UNIT.

Assembly and Mounting

Step 1: Attach the Handle

After unpacking the unit from the box, locate the handle. Remove the (2) Allen Head Cap Screws from the handle pivot and attach the handle to the pivot block with the flat side of the handle towards the upright portion of the block. Tighten both screws with a 3/16” Allen wrench.

Step 2: Attach the Outfeed Extensions

Unpack the (2) 24” long outfeed extensions.

NOTE : These 2 extensions can be joined together first, and then attached to the cutter as an assembly or the second extension may be left off until all alignments are done. Go to step 4 if you want to join them as an assembly first, then proceed to step 3 after mounting. The first extension will have an offset bracket to mount to the unit. The second extension will have a flat bracket to mount onto the right side of the first extension. Remove the (2)

10 nuts and washers from the right side of the cutter base. Position the

first extension under the base plate and refasten with the (2) #10 nuts and washers. The flat-head Allen socket screws require a 1/8” Allen wrench and the nuts require a 3/8” wrench or pliers to tighten. Do NOT tighten these screws completely just yet.

DO NOT TIGHTEN COMPLETELY AT THIS TIME.

Step 3: Align Stop to Cutter Fence

The production stop is adjustable (if necessary) to allow perfect alignment with the notch in the stop to the forward edge of the indexing fence on the cutter. Before making any adjustments on the stop, try to align the edges marked with (X) by moving the entire extension towards the front of the machine. Screws (A) should still be slightly loose, to allow movement of the extension fore and aft. If the points of reference (X) still aren’t close enough, loosen Screws(B) and try to get further movement of the extension. As a last resort, you can loosen Screws (C) on the stop and move the stop assembly forward to align (X) with the fence.

Step 4: Attach the Second Outfeed Extension

Remove the (2) #10 nuts and washers from the right side of the first extension. Lift the foot bracket away from the extension and place the connector plate with the second extension under the right side of the first extension. Position the foot bracket under the plate and refasten it with the

10 washers and nuts. Tighten the nuts while keeping the two ends of the

extensions tight against each other.

Step 5: Align Extensions to the Fletcher Fillet Chopper Fence

Before tightening the (2) screws that fasten the first extension to the base, it is important to make sure they are in alignment or parallel to each other. With the fence locked forward, set a straight edge or piece of aluminum molding against the fence and check at the 24” mark and the 48” mark on the extensions to be sure the outfeed is aligned with the cutter fence.

Step 6: Calibrate the Stop & Scale to the Fletcher Fillet Chopper

When the extensions are made, the scales are mounted so that they will measure a little short. This will be approximately 1/16” – 3/32” so that any extension can be adjusted to any machine. After the final assembly is complete and the extensions are in alignment with the cutter unit, a test cut should be made with a piece of the fillet to check the actual cut dimension versus the measured cut. Using the Zero (0) line on the stop, and measuring the fillet at its longest point will give the most accurate reading. Set the (0) line at the far right of the stop to 6” on the scale. Finger-tighten the nylon screw. Insert a piece of fillet and slide it to the stop. Cut the fillet, and measure from tip to tip as shown. The fillet should measure slightly less than 6”, but it could measure exactly 6”. If short, loosen the Screws (B) on the extension and move the entire extension away from the cutter the amount it was short. If the fillet measured more than 6”, check to see if the extension was tightened with a gap between the extension and the cutter. If not, call Fletcher Terry.

Step 7: Mounting

It is recommended that you mount the Fletcher Fillet Cutter either to a sturdy work table or to a strong piece of board which can then be clamped to a work table if you need more mobility. This will provide stability and safety for you and your employees during its use. Use the mounting plate attached to the rear of the filter chopper. The hinges on the mounting plate allow the unit to lift for easy cleaning. USE CARE WHEN CLEANING UNDER THE UNIT—THE BLADES ARE VERY SHARP. This completes the assembly and setup portion of this manual. Please be sure to read the operating instructions for complete information on cutting fillets to the correct length, and how to determine the cut length of any fillet or slip molding.

Let’s Talk About Fillets

Fillets, slips, lip liners, or trim can come in various shapes and sizes. The basic half-round lip or ogee curve are some of the most popular, but many companies now make fillets to match many of their moldings, both in finish and detail. When cutting a fillet, you have to measure the point where the rabbet edge of the fillet turns up to become the shape of the fillet. This is the normal point of reference. At right are some examples of fillet shapes as shown from the profile view. In each example, themeasuring point is shown as an arrow. Fillets can be used in mats with a straight-cut edge, or more commonly in a mat with a reverse bevel. The latter makes it easier to fit the fillet in the opening with no mat edge showing. Measuring fillets inside the mat opening with a tape measure or yardstick is one way to get the dimensions. The measurements would then be transferred to the scale on a cutting unit to get the final fillet sizes.

It would probably be necessary for you to check the cut piece in the mat opening and then shave the fillet to size using this method. Using a Fillet Master® from Fletcher-Terry is one way to get the dimensions without using a scale or tape measure.
There are also two ways to mark and measure a mat opening without using a tape measure. Shown below are two accepted ways. #1 shows the fillet with one end cut, then held in the opening with the rest of the fillet extending below the mat. Mark straight across the fillet with a razor blade or sharp instrument. Cut to the mark where it crosses the arrow point of the fillet as explained above. #2 shows (2) small pieces of the same fillet taped lightly into opposing sides of the opening. A fillet with one end cut is held in the opening with the rest of the fillet extending below the mat. Mark across the 45º with a sharp pencil as it crosses under the small fillet corner. Cut the fillet at the pencil mark.

Operation

Measure Opening

Measure the inside dimensions of the mat opening and record them. These dimensions are used to set the length of the cut of the fillet. Note: If you are using a Fillet Master® from Fletcher-Terry, set the unit for the width of the fillet rabbet as explained in the instructions for the Fillet Master®. Then set the length for one side of the mat opening. Be sure the Fillet Master is calibrated for your Fletcher Fillet Chopper scale.

Position Fence

Make sure the sliding fence is indexed to the forward position (towards the blades) and locked with the thumb lock bar between the lock pins and fence. Identify Rabbet on Fillet

Set the fillet into the machine from the left side and cut one 45° end. Slide the cut fillet over to the production stop and align the rabbet edge of the fillet with one of the horizontal lines on the stop. As shown at right, the fillet aligns with line #3 (hash mark between line 2 and line 4). Using the projected line to the scale, slide the stop out to the desired dimension for one side of the mat opening and tighten the screw on the production stop. Note: If you are using the Fillet Master®, set the unit into the throat of the Fletcher Fillet Chopper making sure the stop is set far enough to the right to be out of the way. Start with the knob in the center of the blades. Slide the Fillet Master gently back against the fence and right side of the machine vee opening. Slide the production stop to the left until it touches the tip of the Fillet Master® and engages the notch in the stop. This setting will cut the correct size of the fillet if the Fillet Master® is set properly.

Adjust the Indexing Fence (if necessary)

If the fillet/trim being cut is 1/4” – 1/2” wide and can be cut easily in one chop, the fence should stay in the forward-locked position during all cutting (toward the blades). If the fillet is wider than 1/2” or is very hard wood, you might want to index the fence backward (away from the blades) to allow for nibbling or multiple cuts. For very wide fillets such as 1” to 1-1/4” in width, multiple cuts will give you the best results. (It may only require one extra cut.) The production stop is designed so the fillet can slide forward and backward after lifting the end over the thin flag. Always set the stop to the desired measurement while the fence is in the locked position. The locked position is important to achieve accuracy on the final cut. The thumb lock bar is raised to clear the lock pins so the fence can index backward or forward. The nibble cut positions are estimated. The final cut position is with the fence in the full forward and locked position (toward the blades). The thumb lock plate (position plate) is locked in place by the two small pins. Note: When nibbling, the end of the fillet slides over the thin flag of the stop, and the outside angled cut of the fillet slides along the raised step on the stop.

Accessories

Left Infeed Table Part # 04-901
Replacement Blades (set of 2) Part # 05-700

Call your local distributor for ordering information.

Spare Parts

If you require spare parts, please contact Fletcher-Terry for assistance at 1.800.843.3826 (in the U.S.) or 860.677.7331 (outside the U.S.). A list of spare parts and corresponding diagrams are provided in the following pages for reference:

SPARE PARTS

REF. NO. QTY PART NUMBER DESCRIPTION

1	1	460 013 550	HANDLE RUBBER GRIP
2	1	460 013 537	HANDLE
3	2	460 013 541	1/4-20 x 1” SOCKET HEAD CAP SCREW
4	1	460 013 533	HEAD PIVOT BLOCK
5	1	460 013 505	1/4” x 1” SHOULDER SCREW
6	2	460 013 503	GIBB
7	21	406 004 130	#10 FLAT WASHER
8	4	460 013 540	#10-24 x 1/2” SOCKET HEAD CAP SCREW
9	2	460 013 504	HEADWAY
10	1	460 013 535	HANDLE PIVOT BLOCK
11	1	460 013 536	CHAIN CONNECTING LINK
12	2	460 013 579	SPRING DOWEL
13	1	460 013 578	TOP SPRING PLATE
14	1	460 013 576	HEAD BLOCK
15	2	460 013 541	1/4-20 x 1” SOCKET HEAD CAP SCREW
16	12	460 013 538	#10-24 x 1/2” FLAT HEAD SOCKET CAP SCREW
17	1	460 013 586	SPRING
18	1	460 013 585	SPRING TUBE
19	1	460 013 562	BACKPLATE
20	1	460 013 575	HEAD BRACKET
21	1	460 013 534	BACK PIVOT BLOCK
22	2	460 013 539	#10-24 x 3/4” FLAT HEAD SOCKET CAP SCREW
23	6	460 013 546	1/4” x 1/16” FLAT WASHER
24	2	060 005 700	BLADES
25	1	460 013 530	LEFT BED PLATE
26	1	460 013 531	RIGHT BED PLATE
27	10	460 013 539	#10-24 x 3/4” FLAT HEAD SOCKET CAP SCREW
28	2	460 013 561	MOUNTING BLOCK
29	4	460 013 538	#10-24 x 1/2” FLAT HEAD SOCKET CAP SCREW
30	1	460 013 560	BASE PLATE
31	8	460 013 538	#10-24 x 1/2” FLAT HEAD SOCKET CAP SCREW
32	8	406 204 000	#10-24 HEX NUT
33	4	460 013 542	#10-24 x 3/8” SLOT ROUND HEAD SCREW
34	2	460 013 563	FRONT FOOT BLOCK
35	2	460 013 564	BRONZE BUSHING
36	2	460 013 544	3/8” x 2” SHOULDER SCREW
37	6	460 013 547	5/16” x 1/16” FLAT WASHER
38	2	460 013 543	5/16-18 HEX JAM NUT
39	2	460 013 508	POSITION PLATE ASSEMBLY
40	1	460 013 565	FENCE
41	2	460 013 567	8-32 SLOTTED SHOULDER SCREW
42	2	406 004 130	#10 FLAT WASHER
43	1	460 013 566	RATCHET PLATE
44	2	460 013 545	SURFACE MOUNT HINGE
45	4	460 013 538	#10-24 x 1/2” FLAT HEAD SOCKET CAP SCREW
46	1	460 013 532	BLADE GUARD
47	1	460 013 549	CAUTION LABEL
50	1	060 013 501	STOP ASSEMBLY
51	1	460 000 001	1/4-20 NYLON THUMB SCREW
52	1	460 013 592	BASE-EXTENSION MOUNTING BRACKET
53	2	460 013 591	ALUMINUM EXTENSION
54	1	460 013 597	EXTENSION-EXTENSION MOUNTING BRACKET
55	2	460 013 593	OUTFEED SUPPORT BRACKET
56	2	406 204 000	1/4-20 HEX NUT
57	2	460 013 594	1/4-20 x 1 1/4” HEX HEAD SCREW
58	1	460 013 595	RIGHT OUTFEED SUPPORT – 48”

Back Plate & Head Assemblies

Base Plate & Fence Assemblies

Extension Plates & Adjustable Stop

PRODUCT WARRANTY

The Fletcher-Terry Company warrants the machine purchased to be free from defects in parts and workmanship for (1) one year from the date of purchase. The Fletcher-Terry Company warrants that it will repair or replace any such defective machine or replace parts, providing the machine has been under normal use and service and the defective part or machine is returned to The Fletcher-Terry Company at the purchaser’s expense. The Fletcher-Terry Company must authorize the return in writing. Proof of purchase must be submitted to validate warranty coverage. The warranty is in lieu of all other agreements and warranties expressed or implied. THE FLETCHER-TERRY COMPANY DOES HEREBY EXPRESSLY DISCLAIM ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The Fletcher-Terry Company does not authorize any company employee or representative to assume for it any other liability than that set forth in this Product Warranty. The Fletcher-Terry Company shall not be liable for any damages or losses, whether incidental or consequential or direct or indirect, arising out of the use or abuse of this machine. In any event, THE PURCHASER’S SOLE AND EXCLUSIVE REMEDY UNDER THIS OR ANY OTHER WARRANTY IS LIMITED TO RETURN OF THE PURCHASE PRICE PAID FOR THIS MACHINE. Blades are not included in the warranty.