DW735 Planer and Byrd Shelix Head Cutter

[Bob D.]

Or I guess I could sell the three unopened sets of DeWalt blades I have...

Bob I would definitely make the switch sooner!

LOL, sooner became later, much later, as I am just now looking into changing the cutter head before I start working with this 8/4 cherry. I need to plane it at it's current width which is at the max capacity of the planer or 13". So even though I have a few sets of blades left I am going to make the changeover today as I figure it will be easier on the machine.

I've got the cover off and cleaned up inside as best I can before I start taking things apart. I finally opened the box the Shelix head came in back in Oct 2017 !  [huh] Looks to me on just a visual that the diameter of the cutters is close to the OD of the larger bearing. There was nothing in the box as far as instructions. It says go online for installation instructions so that's why I am here at the PC. I will read and take a crash course at YT University  [big grin] before I begin. And maybe drop back in here for some advice from those who have been there already if I need it.

Anyone need some DeWalt blades for their DW735? I think I have three sets in unopened packaging.

 

[Cheese]

It's really straight forward Bob...took me maybe 60-90 minutes or so.

Two things, make sure you have the correct snap ring pliers size or prepare yourself for a 20 minute swearing session.  [big grin]

Secondly, make sure you have all the parts/washers from the original Dewalt set. In the process of moving the Dewalt parts across the room to the workbench, one of the washers fell off and finding that single item led to a 2nd swearing session.  [smile]

You'll be blown away with the noise reduction.

 

[Mike Goetzke]

[member=44099]Cheese[/member]  Did you ever get a resolution to this issue?

Well not really [member=60648]Nailed IT[/member] . [sad]

I did find out that Byrd is purchasing the inserts from Tigra a German firm. The carbide is T10MG (Micro Grain) one of the toughest that Tigra offers. Unfortunately, this particular insert shape is offered only in T10MG. Because of the chipping issues I encountered I was thinking about trying the insert in a different carbide material/binder configuration but that appears to be a no-go.

Byrd also mentioned that they were unaware of any brittleness issues with the inserts.

I did this mod way back in 2010. I didn't even use or try it out until about two weeks after I modified it and I couldn't believe it when I saw hunks of carbide on the planer bed! Me being me I dug into it and the couple of broken inserts were not seated properly. So I took them all out, cleaned it up, and reseated all the inserts. Then I found some of the holes were not tapped deep enough! Luckily I was able to re-tap them deeper. After this it worked fine for about a year until I replaced it with a Grizzly for my big kitchen remodel.

 

[Bob D.]

It's really straight forward Bob...took me maybe 60-90 minutes or so.

Two things, make sure you have the correct snap ring pliers size or prepare yourself for a 20 minute swearing session.  [big grin]

Secondly, make sure you have all the parts/washers from the original Dewalt set. In the process of moving the Dewalt parts across the room to the workbench, one of the washers fell off and finding that single item led to a 2nd swearing session.  [smile]

You'll be blown away with the noise reduction.

Couple questions since you've been through this:

I watched a couple videos and I noticed in the one that is linked to from Byrd's website (  ) that he does not mention using Loctite on the drive pullet nut but it looks like he did use it as I see some blue on the pulley. So did you use Loctite.

No mention of torqueing anything which seems weird to me. Just not the way I am used to working. Where I worked if the manual or procedure didn't give you a torque value then you went to the generic torque procedure and looked it up for whatever type/size fastener you had. Stuff like cover screws who cares but the screws retaining the gears, the drive pulley, etc. I would expect a torque value.

They didn't reinstall the shaft lock during reassembly. The manual says it is no longer necessary but why? I thought it was an interlock to prevent the shaft from turning when the cover was removed. How is that not necessary with the Shelix head. I guess it would be a PITA when you were rotating the cutters. That's the only reason I could see they left it out.

Need to run out and get some blue Loctite, all I have is red.

 

[08G8V8]

[member=44099]Cheese[/member]  Did you ever get a resolution to this issue?

Well not really [member=60648]Nailed IT[/member] . [sad]

I did find out that Byrd is purchasing the inserts from Tigra a German firm. The carbide is T10MG (Micro Grain) one of the toughest that Tigra offers. Unfortunately, this particular insert shape is offered only in T10MG. Because of the chipping issues I encountered I was thinking about trying the insert in a different carbide material/binder configuration but that appears to be a no-go.

Byrd also mentioned that they were unaware of any brittleness issues with the inserts.

I did this mod way back in 2010. I didn't even use or try it out until about two weeks after I modified it and I couldn't believe it when I saw hunks of carbide on the planer bed! Me being me I dug into it and the couple of broken inserts were not seated properly. So I took them all out, cleaned it up, and reseated all the inserts. Then I found some of the holes were not tapped deep enough! Luckily I was able to re-tap them deeper. After this it worked fine for about a year until I replaced it with a Grizzly for my big kitchen remodel.

I saw another post a few days ago mentioning the Grizzly head, but looks like they have discontinued it.

Sent from my iPad using Tapatalk Pro

 

[Bob D.]

I completed the 'upgrade' without any issues. Had to go to two places before I found blue thread locker.

I've been using it on some scrap pieces before I run my project wood through to see how it performs.
It is leaving a nice, smooth cut and no snipe so I am happy with that.

However, I'm sorry I have the reduced OD version and not the OEM version. I don't remember if the
OEM version was even available in 2017. I think if it was I would have taken that choice. Now I have to
work on recalibrating everything to the new head diameter if that's possible. The depth of cut indicator
I know has some adjustment but I don't know if it's enough. I know it's just a rough measurement but
it does help when setting depth of cut. Right now it seems like it reads double what is being removed.
If I set it for 1/16 then I get about 1/32. I haven't moved the scale yet but I know how to do it and it
only takes a second. Resetting the depth stops will take a bit longer I think. I will have to read up on
the procedure for doing that. And the Wixey needs to be reset too.

I will hang on to the original head and all the parts removed of course. I packed them in the box the
Shelix head came in along with a copy of the instructions, the lockbar and screws I removed, and even
the old blades as the 'used' side still have plenty of life in them and the second side is still new. The
other three sets of blades I will put in the classified section here or on eBay if they don't move here
in a week or two.

It does run quieter. Not enough that you want to stop wearing hearing protection but still less noise.

I wish I had made the change years ago. I will probably never buy blades or inserts again. If the inserts
last as long as they claim I should be a couple years away from my first 'blade change' so to speak. With
three more sets of cutting edges it should be a long time before I need another set of inserts.

 

[Cheese]

1. I can't specifically remember using Loctite however, I always have blue, red & green on hand so maybe it was just a natural thing and I didn't put any thought into it because Loctite was readily available.

2. The only torque specs they listed was for the carbide inserts. For the rest of the assembly I do as you've suggested, I base it off of the fastener size.

3. I also did not reinstall the shaft lock. It's sitting inside the box that holds the original Dewalt cutter assembly.  [smile]

 

[Cheese]

Well congrats Bob...

I installed a Wixey 510 readout, it works well.

This is the type of finish that you'll get. The troughs are about .001" deep. They sand out easily.

[attachimg=1]

 

[kevinculle]

I was able to adjust the depth stops to match the smaller diameter Byrd head.  I use a Wixey digital depth indicator so the other scales aren't an issue for me.

 

[mike_aa]

For those of you who have the smaller diameter Shelix, it looks like they have an option to trade it in for the full size one.  See this on their website

Mike A.

 

[Bob D.]

For those of you who have the smaller diameter Shelix, it looks like they have an option to trade it in for the full size one.  See this on their website

Mike A.

DITH, when did they post that? If I had known about that I would have never installed the cutter I have today.
I hate to go through the whole procedure again but I think I will call them tomorrow. I'm not really loving the
reduced diameter but as I said I don't remember their being a choice back in 2017. Maybe there was and I went
with this one but the reasoning for doing so escapes me.

If you have to remove all the inserts to install the OEM cutterhead, why do they install the inserts from the factory?
That just means you have to remove them all. To me would be better to ship the inserts loose. Would save some
time at the factory and also the buyer would not have to remove them to install.

 

[kevinculle]

I believe the larger diameter cutter head does ship without inserts installed.  That's the installation advantage of the smaller diameter head although I did torque check the inserts after I installed the small diameter head on my DW735.  As I recall they were pretty much spot on with maybe a few getting minor rotation before clicking the torque wrench...that could easily be attributed to calibration differences in my torque wrench vs. Byrd's.  I installed my Byrd head in about 2015 and I am sure that only the small diameter head was offered then, not sure when they added the standard diameter head.

 

[mike_aa]

[member=60461]Bob D.[/member]  No clue as to when that was posted.  I spotted it last night when I was checking their website for more information on installation.  Maybe it would be helpful to give them a call.

Mike A. 

 

[Cheese]

For those of you who have the smaller diameter Shelix, it looks like they have an option to trade it in for the full size one.  See this on their website

Thanks for that [member=30413]mike_aa[/member]  [smile] [thumbs up]

I just checked mine and it was also purchased in August of 2017. Byrd item B4725 was the reduced diameter cutter head.

I've also had some issues with the inserts chipping very lightly around the edges and I wonder if the reduced diameter has something to do with that?  I contacted Byrd Customer Service with details & photos of the inserts and they responded that they were unaware of any issues, but that was 3-4 years ago. Obviously times change and Byrd now has more data/feedback on the smaller diameter head.

I'll be sending mine back for the larger diameter item.  Thanks again Mike... 

 

[Bob D.]

[member=60461]Bob D.[/member]  No clue as to when that was posted.  I spotted it last night when I was checking their website for more information on installation.  Maybe it would be helpful to give them a call.

Mike A.

Yes, I called this morning and left a message, waiting for a call back. Thanks for posting that.

I can't believe that after only 5 minutes use and a couple hours to install I am thinking of taking this back out. Tough part will be waiting for the two weeks or whatever the turn around time is with my planer sitting all apart in the shop.

I have a sewing table I need to get built for my sister's antique sewing machine and want to have ready in September when they are planning to drive over from Indiana to visit. It breaks down into five pieces for transport which is why I want to use the 8/4 cherry and bookmatch the pieces that are hinged.
https://www.etsy.com/listing/955711183

 

[kevinculle]

In all the time I have used the Byrd head on my DW735 I think I've only rotated a few inserts for small edge chips and replace one or two that cracked through the screw hole.

 

[08G8V8]

[member=60461]Bob D.[/member]  No clue as to when that was posted.  I spotted it last night when I was checking their website for more information on installation.  Maybe it would be helpful to give them a call.

Mike A.

Tough part will be waiting for the two weeks or whatever the turn around time is with my planer sitting all apart in the shop.

I’m curious what the turn around time for this swap would actually be. If you go to the byrdtoolexperts.com site, they clearly state a 24-32 week lead time for new orders, but if you go to the shelixheads.com site, I don’t see any lead time statement. 

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[Bob D.]

In all the time I have used the Byrd head on my DW735 I think I've only rotated a few inserts for small edge chips and replace one or two that cracked through the screw hole.

Do you have the OEM cutter or the small diameter cutterhead Kevin?

I'm not liking the smaller diameter and the increased feed roller pressure.
And after reading that it can damage the planner I don't want to use it at
all. I did a couple test cuts after the install but no plans to use it until I hear
back on the possibility of an exchange.

I wish I had known before I installed the thing yesterday. :-(

I may end up removing it and going back the DeWalt cutterhead with
straight blades if its going to take a couple months for a replacement.

That would suck now that I have seen how much better the cut is with the
Shelix. I'm not worried about yanking it in and out a couple times.

That's the beauty of being retired, I've got all the time I need.  [big grin]

Until I'm not hear anymore that is.  [sad]

 

[BobA]

I have had the smaller diameter head in my 735 for at least 6yrs, and have had zero issues.  I use rough cut wood for all of my projects so the planer is used in every project.  I haven't bothered recalibrating the depth stop because I don't use it.  I installed a Wixey planer gauge that I use as a general guide for board thickness and then verified with a caliper. 

 

[Cheese]

What I’m finding interesting is that an item that was once a mainstay product for them (Shelix with a small cutter head diameter) has now been relegated to "item no longer available." That’s a major alarm for me. The secondary issues of increased feed roller pressure and additional snipe only add to my angst. I’ll give them a call tomorrow and inquire about the delivery time frame. If it’s 2-3 weeks, I can live with that.

Speaking about snipe, I have noticed that if I keep my final cut to about .005" I don't have any snipe, more than that and I do have a snipe issue.