A simple, shop-made jig makes this a simple task. Click image to enlarge

The Tormek Instant Replication Method

Simple Speed & Accuracy

Text & Photos by Tom Hintz

  The mention of this Instant Replication (IR) Method in the Tormek manual is rather small, and may escape the notice of some readers. The value of this technique is substantial in terms of time and tool life. On those counts alone, the IR method belongs in the repertoire of all Tormek users.
   While the IR method is most often associated with sharpening bowl gouges with the SVD-185 jig, I have found it equally useful when sharpening roughing gouges held in the Open Saddle of the Multi Jig, (SVS-50).
   The photos and story that follow are based on sharpening a bowl gouge using the SVD-185, but the procedures are the same with Multi Jig (SVS-50) and the Short Tool Jig (SVS-32).

How It Works

   The IR method is based on a simple shop-built wooden gauge block that both establishes the distance of the Universal Support to the stone wheel and the length of the tool protruding from the SVD-185.
   The width of the IR gauge block is used to establish the distance of the Universal Support bar from the stone by holding it on edge against the stone and sliding the support bar against it. The tool is then inserted in the SVD-185 and, with the IR gauge block on the edge of a table or bench, the tip of the tool is placed against the stop and the SVD-185 slid up against the end of the IR block. Lock the tool in the SVD-185 and you are ready to sharpen. It literally takes longer to read this than to actually set up to sharpen.

Measure the distance from the stone wheel face to the inside edge of the support arm and add 1/16" or so. Sand the IR block's width until it just slips in this space. Click image to enlarge

Build the Instant Replication Gauge Block

   To build the IR gauge block we have to start with a setup known to be correct. It is easiest to make the IR gauge block after sharpening a tool but leaving the tool locked in the SVD-185 and the Universal Support in position. I use ¾"-thick plywood for my IR gauge blocks because scraps are plentiful and it's easy to use my brad nailer to help install the cross pieces quickly and accurately.
   To establish the overall length of the IR gauge block, measure how much of the tool protrudes from the SVD-185 and then add 2" to that. For the rough width of the IR gauge block, measure the distance from the inside edge of the Universal Support bar to the stone wheel face, and then add 1/16" to 1/8" to that dimension. Cut a strip of plywood to the rough length and width dimensions.

Use the tool in the SVD-185 jig to place the top crosspiece. Glue and brad in place making sure the tool is touching it's side. Click image to enlarge

   Trim the width of the plywood to fit between the Universal support bar and stone wheel snugly. I used a stationary belt sander for this to help keep the width constant over the length of the plywood piece.
   Cut two ¾"-wide strips of plywood for the cross pieces, keeping them slightly shorter than the width of the jig body so they do not interfere with setting the Universal Support bar. Attach one crosspiece to the IR gauge block, flush with the end. (I used a little glue and brads) This will be the bottom side of the IR gauge block.
   Hold the face of the SVD-185 (the tool still clamped in place) against the edge of the IR gauge block and attach the other crosspiece to it's top side, with its side touching the end of the tool.
   Let the glue dry and the IR gauge block is ready to use.

(Top) Use the width of the IR block to set the Universal support arm. (Bottom) slide the jig against the end of the IR block, extend the chisel until it contacts the crosspiece and lock it down. That's it! Click image to enlarge

   While you are waiting for the glue to dry, mark the IR gauge block with the tool it is meant for and the angle setting of the knuckle if the SVD-185 jig is being used.

Using the Instant Replication Gauge Block

   Set the Universal Support arm by holding the IR gauge block on edge between the stone wheel and the arm. When the IR gauge block just slips between the Universal Support arm and the stone wheel, lock the arm in place.
   Place the IR gauge block over the edge of a table or bench, the bottom crosspiece butted against the edge to prevent the jig from moving. Insert the tool into the SVD-185 and then hold it's face against the end of the IR gauge block. Slide the tool forward until it contacts the upper crosspiece and then lock it into the SVD-185.
   Though this setup procedure is extremely accurate, I always color the chisel bevel with magic marker and double check that the bevel of the tool is meeting the stone flush. If a correction needs to be made, they are always very small and done quickly.

Once you use the IR gauge block a couple of times, the speed with which you can set up to re-sharpen a bowl gouge accurately will amaze you. The next time you are turning a stubborn bowl there will be no reason not to take two minutes, literally, to freshen the edge on your gouge.    

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