When you use the DeWalt735 (DW735) planer to plane boards, do you find that the planing results are sometimes subpar? The wood surface may have tear-out and snipe. In that case, you need to upgrade the straight cutterhead on your DW735 to a helical cutterhead.
Upgrading or replacing the cutter shaft requires you to disassemble the DW735, which is a delicate job. This article will give you detailed instructions on disassembling a DW735 and how to install a helical cutterhead on a DW735 planer.
Also Read: How to Choose the Best Cutterhead for DeWalt 735 & 735X
Installation Instructions
In this section, we start straight away with the steps for the removal and installation of the cutterhead on a DW735 planer. Here is a video on how to do it. You can watch it as a reference.
The tools you need:
- Snap ring pliers
- A hammer or a mallet
- Needle-nose pliers
- Allen key (also Hex key)
- 6mm and 24mm socket
- Phillips screwdriver
- WD-40
Remove the Top Cover
Now, we come to the first step of disassembling the DW735 planer - removing the top cover. Follow us and have a try.
Loosen the 4 screws with the included T-wrench to remove the top cover. Remove the 3 red wing nuts of the dust shroud and keep them safe. Take the dust shroud out of the top of the DW735 thickness planer.
Then you can see that the cutterhead is exposed. If the screws on the cutterhead are not visible, use a piece of scrap wood to rotate it until the screws are accessible. Next, remove the cutterhead lock lever, which prevents the cutterhead from rotating when you change the knives.
There are three knives, so you need to remove 24 screws in total. Put them in the small screws bin on the front panel of the DW735 planer. Use a magnet on the top of the T-wrench to attract the blades to keep your fingers from getting cut.
(Image Source: DeWalt)
Disassemble the Left Part
The second step is to disassemble the left part of the DW735 planer, the gearbox. But if you want to remove the right part first, that's fine too. Just skip to the next section. Here are the steps to remove the gearbox.
- Use the T-wrench to remove the three screws on the gearbox.
- Remove the two snap rings with the snap ring pliers. Don’t overstretch it.
- Use a pair of needle-nose pliers to disconnect the top spring from the tensioning lever. Just let it hang on the bolt.
- Take off the chain and sprockets, and then remove the spacer for one sprocket gear.
- Remove the three socket head screws that hold the gearbox in place.
- Remove the screw on the gear lever to take the gearbox off.
- Spin the speed selector to pull the gearbox off and leave it hanging.
- Remove the snap ring with the snap ring pliers.
Disassemble the Right Part
This section will give you the steps to disassemble the handle (crank). Let's keep reading.
- Loosen the screws on the handle and the cover with the T-wrench to expose the chain and sprockets.
- Use the needle-nose pliers to disconnect the spring on the right side from the tensioning lever.
- Take off the tensioning arm with a Phillips screwdriver.
- Remove the two screws on the chain with an Allen key to take off the chain and sprockets.
- Pull the pulley belt out with one hand and then assist it with the other hand.
- Use a piece of wood to block the cutterhead from rotating, and then use a 24mm socket wrench to remove the hex nut.
- Remove a small key and a spacer. Keep them in a safe place and don’t lose them.
- Use your snap ring pliers to remove the snap spring.
Mount the Helical Cutterhead
Now that you've completed the basic disassembly of your DW735, it's time to remove its cutter shaft and replace it.
All you need to do is align the bearings on the side of the gearbox with a right-sized wooden stick and hit the stick with a hammer. If you find there is some clogging, you can lubricate it with a lubrication product, such as WD-40. Then, pull out the straight cutterhead.
Usually, bearings after a hit are no longer usable, but fortunately, FindBuyTool's helical cutterhead comes with pre-installed bearings.
- Use a 6mm socket and remove the gear on the end of the straight cutterhead.
- Reinstall the gear on the new helical cutterhead.
- Lubricate the exit and entry openings of the DW735 planer.
- Place the new cutter into the planer. You can use a hammer again to fully install it.
- Use the snap ring pliers to install the snap ring in place.
Assemble the DeWalt 735 Planer
After the cutter shaft is installed, assemble the planer crank, gearbox, and top cover in the reverse order of disassembly. Next, use a screwdriver to put the carbide inserts on the helical cutterhead. Make sure the cutter shaft is clean before the insert installation.
After all the parts are correctly in place, start the machine to see if the helical cutterhead is installed and working properly.
Parting Shot
When removing the DW735 planer components and installing the helical cutterhead, it is important to be safe and careful. The disassembled parts must be kept in a safe place in case of loss.
If you think it's hard to replace the helical cutterhead, just buy a planer with a helical cutterhead.
FindBuyTool produces a high-quality and affordable thickness planer with a helical cutterhead. This powerful tool offers precise cuts with low noise, high speed, and high-temperature assistance. The 4-row helical cutterhead, featuring 40 tungsten carbide inserts, reduces tear-out and snipe.
Most importantly, inside the box you receive, you get a thickness planer with a helical cutterhead that has already been installed. Only a few accessories need to be assembled.
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FAQ About How to Install a Helical Cutterhead on DW735
#1. Can you put a helical head on a DeWalt planer?
Yes. Both helical and spiral cutter heads can be put on a DeWalt planer. You just need to follow the correct method of removing the original straight blades and replacing the helical cutterhead on it. With a helical cutterhead, your planer provides smoother operation, less noise and vibration, and longer service life.
#2. Is a helical or spiral cutterhead better?
Which of the two is better depends on your requirements and budget. If you are more results-driven, a helical cutterhead is the first choice. But if you are on a budget, a spiral cutterhead is also a good choice.
Related Article: Spiral vs. Helical Cutterhead: Essential Differences You Should Know
