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Home > Miscellaneous > New Project: Plans for a Metal Shaper With a Six Inch Stroke

New Project: Plans for a Metal Shaper With a Six Inch Stroke

Material: Cast Iron (Castings) and Steel
Units: (in)

This set of vintage plans was loaned to me by a friend who has had them for many (30+) years. The plans are for a “Six Inch Stroke Bench Crank Shaper” from the Pootatuck Corporation of Stratford Connecticut. However, I can’t seem to find any information about them online. The plans are old enough that I believe they are no longer protected under copyright. If this is not the case, please let me know and I will remove them.


Also, if anyone has any information about this shaper, including pictures or videos of a completed version of this shaper, please post them to the forum.

Which reminds me, for those of you who haven’t heard, has a new forum! The new forum will allow users to communicate with each other more easily and provides a simple way for visitors to share pictures of their projects, ask and answer questions, etc. The forum is free, so please take a moment to register via the “Forum” tab at the top of the page.

One more thing, it looks as though someone used to supply castings for this shaper. If anyone is still supplying castings, please let us know by posting the information to the forum. If not, this might be a good casting project for the furnace my friend Barry is building. Also, if you’d be interested in buying castings for the shaper, please leave a comment below or on the forum.

  Six_Inch_Stroke_Bench_Crank_Shaper_by_Pootatuck_Corp.pdf (7.1 MiB, 2,739 downloads)
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About Tyler

Tyler is a hobby machinist and 3D printing aficionado. He teaches computer programming and web development at Highline College near Seattle. Tyler founded Projects In Metal in 2008 because he was frustrated by the lack of free plans available for hobby machinists.


  1. I was intending to make a Gingery Shaper with a 12″ stroke.

    This design seems rather interesting and a nice set of plans too.

    I think its a going to be cracking project, I post some drawings as I progress.



  2. ConfusedHi All

    Greetings this is my first post from down under. (Melbourne Australia)
    Yesterday I found the plans for the small 6″ Shaper on this site
    Very nice plans indeed.

    But where to source the castings? Not so easy these days. and quite expensive. I think there is an alternative well two actually.
    Firstly the main frame and slide could be made as epoxy concrete castings (These days often referred to as mineral castings).
    Castings made from sand, 5mm aggregate and epoxy resin About 15% epoxy by volume.
    The sliding surfaces will be steel inserts cast in place. as will any bores or other surfaces requiring high precision.

    If your patterns are good enough and you have located the inserts accurately subsequent machining can be avoided. otherwise once cured the metal inserts can be machined in the normal way.   

    With this in mind I have drawn the frame and slide as 3D solids (I use AutoCAD), fairly close to the original but beefed up for epoxy casting. Unlike cast iron where you have to try to keep the wall thickness constant, to avoid hot spots. wall thickness variation is not a problem. Cores can be a lot simpler.

    I did a long write up on Epoxy casting while building an epoxy concrete version of a small tool grinder, the grinder starts after the first page,

    Google the following search:
    new technology in model engineers workshop 
    (I am not sure how to insert an external link on this forum? will the editor accept the link raw?) 


    I used the actual plan as a background raster image and traced over it using autocad

    The finished castings:

    Transparent view to show voids:

    Alternatively The entire design could be reworked to be cut from laser cut 10mm plate steel, and linear bearings. Totally modern…..


    I designed a router with a mate for a not profit Men’s shed a while back that was built that way it works extremely well. The method I would use is to design for self assembly, No welding I hate welding distortion, all bolted mortise and tenon joints.

    The big advantage is speed and accuracy very little machining would be required on the frame, Bull wheel, covers, Drive arm and slide. Flanged or circlip ball bearings would replace all bronze bushings as done in the router, Even the bull wheel could laser cut and say T5 teeth cut on the periphery. timing belt drive instead of gears.


    laser cut cnc router new build mach3 bright men’s shed

    That will find a write up

    Which direction should we go. A classic build or a modern version. Or both?

    It would be good to hear from any other CAD designers on this forum. Maybe we could brain storm.


  3. Wow John, impressive work on the project you posted to Model Engineer! Here’s a link to page 2 where the images start:…..7&p=2

    Feel free to post links in the future as long as the links are relevant to the topic and not spammy.

    I wish you would have posted your project here! You wouldn’t have had a single person give you a hard time. I hate it when people do that. The grinder you made is very impressive!

    Are you seriously considering casting the shaper in the same manner? I’d be delighted to have you write up the project here. I’d put it on the home page. Let me know if you’re interested.