CLARK FOAM PLANER 2003 MODEL SAFETY AND OPERATING INSTRUCTIONS Version 1, 2003
WARNING – SAFETY INSTRUCTIONS This planer is sold as is. The planer is designed for the specific purpose of shaping Clark Foam using the well-known techniques and equipment universally used in the polyurethane foam surfboard industry since 1958. The planer is not suitable for any other purpose and may cause injury or death if used for any other application or if any unorthodox surfboard shaping methods or equipment are used.
TABLE OF CONTENTS INTRODUCTION ............................................................................................................................5 FEATURES ....................................................................................................................................... 5 SERVICE ..........................................................................................................................................7 HELP LINE ..................................................
INTRODUCTION The 2003 Model Clark Foam Planer and tool kit was developed specifically for the professional shaper. It comes fully equipped with every option the majority of professional shapers use. The planer is assembled at Clark Foam from a combination of stock parts, modified stock parts, and parts fabricated by or for Clark Foam. The main body is a Hitachi P20-SB. Clark Foam has sold a modified Hitachi F-20 and P-20SB series planer since 1988. It has proven durability and a good safety record.
- When properly set up the depth adjustment mechanism operates very smoothly and there is almost no backlash or play. The depth adjustment mechanism indicator can be moved to accommodate the individual shaper’s style. The large depth adjustment mechanism knob can be customized using knobs available from Clark Foam and commercially available knobs. The depth adjustment knob’s tension is adjustable. A foam seal keeps dust and debris out of the depth adjustment mechanism significantly reducing maintenance.
SERVICE Clark Foam will repair planers we have sold at the California Factory. Clark Foam stocks and sells the commonly used parts like brushes, triggers, blades, blade holders, depth adjustment components, bearings, foam filters, and knobs. We can usually rob parts we do not stock from new planers being assembled. We can also order any part on the planer. It will probably be easier to purchase parts from Clark Foam rather than from a local repair center because so many parts are modified.
BLADE EXCHANGE SERVICE - BLADE SHARPENING Beginning in 2003 Clark Foam offers a blade exchange service. Here is how it works: The planer owner hands us a set of dull blades and blade holders. The blades may have any amount of wear. The blades and blade holder must not be damaged. We hand the planer owner a set of sharp blades attached to blade holders. The blades might be brand new or they may have been sharpened for their very last time. The blade holder will be in good condition.
WD-40, light oils, Triflow, Teflon, and hard waxes have been successfully used. BASE PLATE MODIFICATION The edges of the rear base plate are left square and sharp on new planers. They were left this way as many shapers want foam dust and wood dust to be pushed ahead of the planer. If the edges are rounded the planer will lift over the dust. The edges can be easily rounded. Caution is advised as aggressive rounding makes the planer tipsy.
The depth adjustment indicator knob that comes with the planer can be eliminated or replaced with any knob with a 3/16" hole. THE DOUGHNUT AND DEPTH ADJUSTMENT INDICATOR In this section we will discuss the most important decision you must make when setting up your planer. Put a lot of thought into this decision for once you glue certain parts together the decision is fairly permanent.
DISASSEMBLY OF THE DEPTH ADJUSTMENT MECHANISM It is important that you remember the position of each part for re-assembly. It might be a good idea to write down the position of each part. The unit will not work properly if a part is missing. (There is also a diagram later in this manual.) Unscrew the large knob, remove the spring washer, loosen the Allen Screw, and remove the DOUGHNUT. Next remove the Teflon washer and drop the front plate assembly out of the planer’s plastic housing.
ADJUSTING THE MAXIMUM CUTTING DEPTH This feature is useful for shapers who use a fixed depth cut and shapers who do not want to make deep cuts. Included with the parts that come with the planer is a ring type spacer. This spacer can be placed on the cylinder attached to the front base plate. This will limit the maximum cutting depth of the planer. To adjust the maximum cutting depth, carefully file or grind down the ring. INDEXING THE BASE PLATES AND START OF CUT This is an important adjustment.
DEPTH ADJUSTMENT MECHANISM ASSEMBLY AND ADJUSTMENT During assembly the following three very important adjustments are made: 1. The direction of the depth adjustment indicator knob is set in the position preferred by the shaper. 2. The depth adjustment knob tension or ease of turning is set. This is dependent on how hard the DOUGHNUT is pressing against the planer housing. This same adjustment is used to eliminate the backlash or play caused by a space between the housing and the DOUGHNUT. 3.
the DOUGHNUT. Check the movement. If it is still too loose repeat the process. This is a key adjustment and due to wear it may need to be repeated later in the life of the planer. 9. Carefully check the way the depth adjustment operates. Check the alignment between the front base plate and the rear base plate to see if it is the desired setting. If anything is wrong repeat the steps above. 10. Tighten the big knob.
4. Fire hazard is dramatically cut. This makes the local Fire Marshall very happy. In areas with tough fire inspection policies this can make the difference between being allowed to operate, or being shut down. Clark Foam has developed a vacuum system for the 2003 Model Planer. We also stock components and supplies for vacuum systems. Our system and components are chosen carefully for optimum vacuum efficiency, high productivity, and a neutral feel on the planer.
To be absolutely sure the problem is the trigger, connect both wires attached to the trigger to a single trigger terminal and plug in the planer. If the brushes are OK and the trigger is OK, look at the wiring in the rear handle and under the back base plate. Next look at the power cord. At some point a voltmeter or voltage indicator may be required. POWER CORD MAINTENANCE AND ADJUSTMENT Since the Clark Foam planers were first introduced we have seen a lot of power cord damage.
REPLACING BELTS The drive belt between the cutter motor and the cutter lasts surprisingly long. They do, however, eventually wear out. To change the belt, turn the pulleys and guide the belt off the pulleys. The only thing that needs to be removed is the guard. Never operate the planer with the guard off. SHAPING TIPS FOR THE 2003 MODEL Until the experienced shaper becomes familiar with any new planer they will have trouble with accurate depth adjustment.
Carefully study all of the options and adjustments for the depth adjustment mechanism. You need to be an expert! This mechanism may take frequent maintenance, as very slight wear will cause a significant change in performance. This mechanism can be adjusted to provide very high performance. It can also be poorly adjusted making the planer very difficult to use! Carefully evaluate custom modifications to the depth adjustment mechanism to fit your style or prior experience.
For length geometry there are three basic scenarios. All three scenarios are modified to some degree as the planer is turned sideways or compound curves are encountered. They are: 1. The first is a perfectly flat surface. Both base plates have 100% surface contact. The longer the planer the straighter the cut will be. 2. Second is a concave surface. This is like the deck nose area on most boards.
- - - - - - While the rear base plate widths of both planers are almost identical, the width of the 2003 Model blade is almost 1/4" wider than the Skil 100 stock blade. Our best guess is that this tends to cause small blade marks in the foam. (Note that if the 2003 Model has the blades adjusted improperly the width could be almost 1/2" wider than the Skill 100 or the blades could be adjusted off center. This would result in problems.
HISTORY We added this section because many people question why Clark Foam is in the power planer business. We also think some history might be interesting to a person who uses power planers to earn their living. In 1988 the Skil Corporation suddenly announced they were discontinuing production of all power planers. Since it was introduced in the 1930’s, the Skil 100 planer had been used for almost all surfboard shaping.
By 2003 four things had clearly changed. First the cost of the Skil 100 parts and planers had increased dramatically. While they are incredibly durable they are slowly wearing out. Some spare parts are being manufactured, but at a very high cost. Second it had became very clear the P-20SB is durable and a good value rather than a “plastic toy”. Third some shapers had gotten really good at using the modified P-20SB and evidently preferred it to the Skil 100 for some or all of their shaping.
TOOL KIT AND PARTS - A “T” socket wrench for changing the blades. A jig for indexing blades using the blade holder. (For an instruction Manual contact Clark Foam.) An Allen Wrench for the DOUGHNUT under the big knob. A depth of cut spacer ring that can be installed to decrease the maximum cutting depth. The ring can be modified. A kit for modifying the indexing mechanism in a separate plastic bag.
