Coping and profile cutting and/or sanding apparatus

A powered coping and profile cutting and/or sanding apparatus is able to impart any shape to the surface of a body of material (17) at any angle, simple or compound, relative to the body of material. The apparatus comprises a reciprocating "frame"(36) encasing thin stacking metal sheets (42) which are adjustable in a forward/backward direction for allowing multiple shape setups. The sheets (42), which are oriented vertically, have saw teeth at their top sections (42a) and no teeth at their bottom sections (42b). Adhesive-backed sandpaper (78) is affixed to the bottom section (42b) after the shape is set. This allows a cutting phase and a sanding phase with the same profile. The entire reciprocating frame (36) pivots multidirectionally within two planes, and may be locked at any angle. The reciprocating frame (36) is movable in a forward/backward direction. The body of material (17) being cut is immovably clamped, and the frame (36) is moved into the body of material (17) for the cutting and/or sanding operation.

BACKGROUND 
1. Field of the Invention 
This invention relates to the working of wood and other materials, 
specifically to powered coping apparatus and tools, such as bandsaws, 
jigsaws, and scrollsaws used in the cutting of shapes into materials. 
Additionally, this invention relates to powered profile sanders, used in 
the sanding of profiled materials. 
2. Description of Prior Art 
The utilization of various types of power saws to shape-cut materials has 
been in common practice since the advent of the industrial revolution. 
More recently, power tools have been utilized to perform the difficult 
task of cutting shapes in materials, defined as "coping". Additionally, 
power tools recently have been utilized to perform the difficult task of 
sanding intricate shapes which already have been cut into materials. 
However, due to the need for multiple tools and multiple shape setups, as 
well as a required high skill level to operate the tools, only a small 
number of artisans can accomplish these tasks. Moreover, present 
technology has certain inherent limitations, such as an inability to 
effectively cut and sand shapes into the side, top, bottom, and end of 
materials, and the necessity of separate tools and tool setups to saw and 
then sand intricate shapes into the material. Additionally, present 
technology requires two separate setups to create shapes and their 
corresponding negative shapes. 
For example: the saw shown in U.S. Pat. No. 5,136,904 to Peters, Aug. 11, 
1992, which is a reciprocating saw blade within a pivotable frame, has the 
following limitations. 
(a) It is difficult to cut shapes into the sides, top, and bottom of 
materials. 
(b) Advanced skill is required to operate this saw. 
(c) The user is unable to adjust the shape of the cutting blades to any 
shape in a minimal amount of time, and is unable to make identical 
multiple cuts. 
(d) It is difficult to cut shapes into materials at both simple and 
compound angles. 
(e) A rough saw-marked texture remains on the material after sawing. 
(f) It is difficult to manipulate or angularly clamp long or heavy 
materials around stationary machinery. 
(g) Two separate setups are required for the original shape and the 
negative of the original shape. 
(h) Only a small number of types of materials can be cut by this tool. 
(i) Profile cuts cannot be done in a precise manner. 
(j) Awkward blade manipulations are required to perform cuts in materials. 
With the exception of items b, f, and j from the above-list, the saw in 
U.S. Pat. No. 5,363,732 to Heasley, Nov. 15, 1994 has the same limitations 
as the saw in the Peters patent. This apparatus includes a circular saw 
that is mounted on two sliding bases. Besides the circular saw there is a 
support for a stylus used to control the positioning of the saw blade by 
traversing a profile template. 
The commonly used bandsaw and scrollsaw have the same limitations as those 
in the Peters patent, except for item j. 
The commonly used jigsaw has the same limitations as those in the Peters 
patent, except for items a and f. 
A profile sanding apparatus is shown in U.S. Pat. No. 2,426,028 to Krueger, 
Aug. 19, 1947 and U.S. Pat. No. 5,554,066 to Bosten et al., Sep. 10, 1996. 
These apparatus utilize a profiled sanding pad coupled to a mechanism to 
provide motion to the sanding pad. These apparatus are limited by the 
following factors: 
(k) There are only a limited number of standard profile sanding shapes 
available to be attached to the sanders. 
(l) These separate sand-alone sanding tools require the artisan to use two 
separate tools, requiring two separate setups for the sanding and cutting 
operations. 
(m) These tools cannot be adjusted to cut non-standard profile shapes and 
cannot be adjusted to create simultaneously both a custom profile and the 
negative of that profile. 
OBJECTS AND ADVANTAGES 
Thus, it is one object of the invention to provide an improved cutting and 
sanding tool which overcome the above limitations of the present 
technology. These limitations include: the need for advanced operator 
skill, limited versatility with respect to the materials and shapes which 
can be cut and sanded, and shape cutting and sanding innacuracies and 
non-repeatability. Additionally, the awkward nature of material handling 
and complex blade manipulations are a limitation. 
Other objects and advantages of the invention include the provision of an 
apparatus which: 
(a) easily cuts and sands shapes into the sides, top, bottom, or ends of 
materials, 
(b) requires minimal skills to operate, 
(c) can be quickly adjusted to create custom cutting and sanding profile 
shapes, 
(d) easily and accurately cuts shapes into materials at both simple and 
compound angles, 
(e) leaves a smoothly sanded surface after cutting material into a desired 
shape, 
(f) allows the material being cut and sanded to be clamped immovably on a 
horizontal surface for the cutting and sanding operation, 
(g) cuts and sands both the original shape and the negative of the original 
shape with only one setup operation, 
(h) is able to cut and sand a broad spectrum of materials, 
(i) provides repetitive high-tolerance shape cutting and sanding, 
(j) achieves the cutting and sanding of complex shapes with a simple 
straight-line blade manipulation, 
(k) adjusts the shape of the sanding profile simultaneously with the 
adjustment of the cutting profile, retaining these shapes for identical 
repetitive cutting and sanding operations, 
(l) requires low skill level to form the custom profile sanding shape with 
zero margin of error between the cutting profile shape and the sanding 
profile shape, 
(m) in one setup operation provides the cutting and sanding profile of both 
the profile and the negative of the profile, 
The possibilities are extensive with respect to the uses of this shape 
cutting device, such as the coping of moldings to other moldings, milling 
of notches or shapes into the sides, top, bottom, or ends of materials, 
coping of material to conform to other shaped materials, etc. The 
possibilities are as diverse as the needs and imagination of the user. 
Further objects and advantages of my invention will become apparent from a 
consideration of the drawings and ensuing description.

REFERENCE NUMERALS IN DRAWINGS 
10. Apparatus push/pull motion handles 
11. Screw clamp mounting block 
12a. Reciprocating motor switch 
12b. Linear actuator motor switch 
13. Screw clamp post tightening knob 
14. Rotating fence 
15. Screw clamp 
16. Rotating fence pivot tightening knob 
17. Body of material 
18. Screw clamp attachment post 
26. Material support surface 
31. Pair of linear slide shafts 
32. Pivot frame 
33(a). linear slides 
33(b). linear slides 
35. Rotating fence pivot hinge 
36. Blade frame 
38. Blade clamp 
39. Sheet of rubber 
40. Turnscrew 
41. Stainless steel 
42(a). Saw tooth section of sheet 
42(b). Sanding surface section of sheet 
43. Stainless steel 
44. Speed reducer 
45. Speed reducer shaft 
46. Motor 
50. Linear slide support frame 
51. Adjustable material support sheet clamp 
52(a). Crank shaft 
52(b). Rod 
52(c). Offset shaft 
53. Adjustable material support sheets 
54. Linear actuator 
55(a). Pillow blocks 
55(b). Shaft and shaft hangers 
56. Linear bearing 
57. Shaft lock and knob 
58. Linear bearing mount 
64. Rotation pivot pin 
66. Rotation pivot slot 
68. Rotation pivot/tightening shaft and knob 
70. Pivot frame 
72. Rotation pivot pin 
74. Rotation pivot/tightening shaft and knob 
73. Rotation pivot slot 
76. Saw teeth 
78. Adhesive backed sand-paper 
79. Sand-paper application tool 
80. Linear cutting interior blades 
81. Blade range of motion indicator arrows 
82. Exterior blades 
84. Standard interior blades 
86. Blade spacers 
88. Alternating saw tooth--set 
90. Saw-tooth--no set 
92. Sawing area (reciprocation within sawing area) 
94. Sanding area (reciprocating within sanding area) 
SUMMARY 
The apparatus of the present invention is used for shaping and sanding a 
body of rigid material. It comprises a plurality of hard flat sheets of 
material which are oriented vertically. The upper portion of each sheet 
contains edges with sharp cutting teeth. The lower portion of each sheet 
contains edges with no teeth. The sheets are stacked and clamped into any 
of a variety of predetermined shapes. Next, an adhesive-backed sandpaper 
material is affixed to the lower portion of the stack of sheets. The 
sheets are set in reciprocating motion and the body of material to be 
shaped is first brought into contact with the upper toothed sections of 
the sheets to effect the shaping of the body. The body is next brought 
into contact with the lower, non-toothed section (to which sandpaper is 
affixed) for smoothing the body. 
Description--FIGS. 1, 2 and 3--Plan view 
A typical embodiment of the tool of the present invention is illustrated in 
FIG. 1. The apparatus has a material support surface 26 which is made of 
1/2" (1.27 cm) aluminum to provide a lightweight, yet strong support 
surface. Four rotatable material fences 14, also made of aluminum, are 
attached to surface 26. Fences 14 can rotate within a 90 degree arc. The 
cutting and/or sanding apparatus is attached to surface 26. 
The apparatus attaches to support surface 26 by means of four bearing 
mounts 58 encasing four linear bearings 56 (see FIG. 3) and four linear 
slide shafts 31 made of a minimum of 1" (2.54 cm) stainless ground stock. 
Linear slide shafts 31 are connected to linear slide support frame 50 (see 
FIG. 3). 
Stack of adjustable material support sheets 53, each comprises of 22-gauge 
stainless steel, are connected atop linear slide support frame 50 (FIG. 
3). Sheets 53 are held in place by clamp 51. Clamp 51 is made of 1/2" 
(1.27 cm) thick aluminum with a 1/8" (0.318 cm) rubber coating attached to 
its underside. 
Connected to linear slide support frame 50 is a pivot frame 70 which is 
attached at rotation pivot pin 72. Pivot frame 70 is attached to pivot 
frame 32 at rotation pivot pin 64. Blade clamp 38 is attached to pivot 
frame 32 by means of linear slides 33a and 33b, both of which are made 
from interlocking brass channels which are graphite lubricated. 
Blade frame 36 and phase lift frame 34 are both made of 3/8" (0.953 cm) 
aluminum (FIG. 2). 
Rotating fence 14 is connected to support surface 26 at rotating fence 
pivot hinge 35. Attached to rotating to rotating fence 14 are screw clamp 
attachment post 18 and screw clamp post tightening knob 13. Attached to 
the screw clamp post is screw clamp mounting block 11. Attached to 
mounting block 11 is screw clamp 15. A body of material 17 rests on 
material support surface 26 and is clamped by screw clamp 15. 
Located at the ends of each pair of linear slide shafts 31 are apparatus 
push/pull motion handles 10. Electric motor switch 12a (consisting of 
either a simple single-pole, single-throw switch or a variable-speed 
control switch) and electric linear actuator motor switch 12b (consisting 
of a single-pole, double-throw switch) are attached to push/pull motion 
handles 10. 
Description--FIG. 2--Front elevation view 
As illustrated in FIG. 2 the cutting and/or sanding apparatus consists of a 
series of frames and drive components comprising a multidirectional-motion 
system for the blades and blade frame. A blade frame 36 made of 3/8" 
(0.953 cm) aluminum encases a series of stacked, thin metal sheets 42 
consisting of 22-gauge steel sheets, having a nominal hardness of 50 on 
the Rockwell scale. These sheets which, are oriented vertically (as 
illustrated in FIG. 6), have saw teeth on their upper sections 42a and no 
teeth on their lower sections 42b. The saw tooth design is 7 points to 1" 
(2.540 cm.) with an alternate face bevel at a 45-degree angle. Each of the 
sanding surface sections of the sheets 42b have a thin layer of rubber 
bonded to each edge. 
The stacking blade sheets are clamped into place by a screw clamp 38 and a 
turn screw 40. A linear slide 33a, made of interlocking brass channels 
which are graphite lubricated, is attached to blade frame 36 and 
phase-lift frame 34. This allows linear movement of blade frame 36, as 
indicated by the arrows in FIG. 2. 
A motor 46 (1.5 horsepower and 1750 RPM) and a speed reducer 44, which has 
a 1-5 ratio are attached to phase-lift frame 34. The latter is made of 
3/8" (0.953 cm) aluminum. A crankshaft 52a, which is made of 1/2" (1.27 
cm) stainless steel, has a 5/8" (1.588 cm) offset shaft 32c located 1" 
(2.540 cm) from the speed reducer shaft's centerline. Crankshaft 52a is 
supported by, and rotates within, pillow blocks 55a. Reciprocal (linear) 
motion is created from the motors rotary motion by the following means: 
crankshaft 52a rotates in a circular motion about the centerline of speed 
reducer shaft 45. Offset shaft 52c rotates in a circle about the center of 
cranshaft 52a. Crank rod 52b is attached to offset shaft 52c. Upon the 
rotation of offset shaft 52c crank rod 52b moves in a reciprocal (linear) 
motion. Rod 52b is attached to shaft and shaft hangers 55b. Shaft and 
shaft hangers 55b are attached to blade frame 36. 
A linear slide 33b, made of interlocking brass channels which are graphite 
lubricated, is attached to phase lift frame 34 and pivot frame 32, 
allowing linear movement of frame 34 as indicated by the arrows in FIG. 2. 
A linear actuator 54 provides an 18" (45.72 cm) travel at a speed of 35 
inches (88.9 cm) per minute. The linear actuator has a minimum load rating 
of 400 lbs, (181.4388 kg.) and is attached to pivot frame 32 and frame 34. 
Description--FIGS. 3-5--Side elevation, exploded perspective and front 
elevation views 
As illustrated in FIG. 3, FIG. 4, and FIG. 5 the apparatus of FIG. 2 is 
connected to a rolling pivot frame (FIGS. 3 and 5). To the rolling pivot 
frame is attached an adjustable material support (FIG. 4). The apparatus 
of FIG. 2 is connected to a rotation pivot pin 64 at pivot frame 32. 
Rotation pivot pin 64 is attached to a rolling pivot frame 70 which is 
made of 1/2" (1.27 cm) aluminum. A rotation pivot pin and tightening nut 
68 travel within a rotation pivot track 66. A rolling pivot frame 70 is 
attached to side pivot pin 72. A side pivot and linear slide support wall 
50 is attached to a pair of linear slide shafts 31. 
Shafts 31 are made of a minimum of 1" (2.540 cm) stainless ground stock. 
These shafts travel in a linear direction through linear bearings 56 which 
are mounted in a linear bearing mount 58. 
Inserted within linear bearing mount 58 is shaft lock and tightening knob 
57 which, when tightened, holds the linear shafts in a static position. 
An adjustable material support sheet clamp 51 is made of 1/2" (1.27 cm) 
aluminum with a 1/8 (0.318 cm) rubber sheet bonded to its underside. 
Sheets 53, made of 22-gauge stainless steel, are clamped to the top of 
support wall 50 by sheet clamp 51 1/32" (0.0794 cm) below the top of 
surface 26. 
Rolling pivot frame 70 is attached to support wall 50 at rotation pivot pin 
72. Rotation pivot tightening shaft and knob 74 are attached to side pivot 
and linear slide support wall 50 and travel within pivot slot 73. 
Description--FIG. 6a, 6b--Perspective view 
As illustrated in FIG. 6 (a perspective view), the stack of sheets forms a 
sanding surface 42b. When the sheets are clamped, an abrasive 
adhesive-backed sheet of sandpaper 78 is attached to sanding surface 42b. 
The sandpaper has a releasable, pressure-sensitive adhesive on its 
non-abrasive face. 
A sandpaper application tool 79 may be employed to push the sandpaper into 
the intricate recesses of the profile. This application tool is a 22-gauge 
by 2" (5.08 cm) by 9" (22.86 cm) strip of stainless steel. Saw teeth 76, 
which are formed in the upper portion edge of the hard, flat sheets of 
material are ground into the edges with 7 points to the inch (2.540 cm.) 
and an alternate 45-degree face bevel. The stack of sheets forms sawing 
surface 42a. 
Description--FIG. 7--Exploded plan view 
As illustrated in FIG. 7, blade spacer 86 is made of 22-gauge stainless 
steel. The spacer is laminated the full length of the sheet. Blade spacer 
86 is laminated to opposing sides of the linear cutting interior blades 80 
(FIG. 9). Exterior blades 82 consist of alternating teeth with no set and 
teeth with a set (see FIG. 9). Standard interior blades 84 consist of only 
teeth with no set (FIG. 9). 
Description--FIG. 8--Perspective view 
FIG. 8 shows the relationship between the sheets with abrasive edges and 
edges to which an abrasive material may be applied (FIG. 6) and support 
surface 26. Sawing area 92 is where the toothed section of the plurality 
of sheets reciprocates adjacent to support table 26. Sanding area 94 is 
where the non-toothed and adhesive backed sandpapered section of the 
plurality of sheets reciprocates adjacent to the material support table 26 
by means of lift created by linear actuator 54 (FIG. 2). 
Description--FIG. 9a, 9b--Exploded plan sectional view, exploded 
perspective view 
FIG. 9 shows all of the components discussed and illustrated in FIG. 7 
stacked so that the plurality of sheets form a predetermined shape. 
Additionally the forward/backward range of motion of the plurality of 
hard, flat sheets of material and displayed by blade range-of-motion 
arrows 81. Also displayed are linear cutting interior blades 80, which are 
interchangeable with the standard interior blades 84, and are utilized in 
the cutting of shapes which have an interior flat spot as illustrated. The 
linear cutting interior blades 80 allow the straight line alignment of 
teeth from front to back of the stacking blade system for the purpose of 
the exact alignment of the positive and negative profiles. The set of the 
teeth creates a kerf which is wider than the blades width, thereby 
preventing the blade from binding in the material as it is being cut. 
Description--FIG. 10--Side elevation 
FIG. 10 shows how stacked sheets 42 are clamped into place by blade clamp 
38. Blade clamp 38 is made of 3/8" (0.953 cm.) aluminum. To the entire 
underside of blade clamp 38 is attached a 1/4" (0.635 cm) sheet of rubber 
39. To the underside of the sheet of rubber 39 are attached two pieces of 
22-gauge stainless steel 41. Pieces 41 cover all but a 1" (2.540 cm.) 
section of the underside of sheet of rubber 39 as illustrated. Stacked 
sheets 42 rest atop 22-gauge stainless steel 43. Stacked sheets 42 are 
clamped by turnscrew 40. 
Operation--FIGS. 1-10 
The manner of using the coping and profile cutting and/or sanding apparatus 
is as follows: 
In order to cope (shape the end of) a length of crown molding (not shown in 
drawings), blade clamp 38 is lifted by turnscrew 40, (FIG. 2) allowing 
movement of sheets 42 in a forward and/or backward direction (FIG. 9). A 
miter cut is made on the end of the crown molding which is to be coped. 
The mitered crown molding is placed on support surface 26 with the mitered 
end of the molding facing perpendicular to the ends of sheets 42 (FIG. 1). 
The mitered end of the molding is pushed into the ends of the sheets 42, 
causing sheets 42 to slide backwards so that the profile of the molding is 
formed at the edges of the sheets (FIG. 9). 
The above discussion and drawings displays that the plurality of members of 
material, which are sheets 42, are arranged in a plurality of contiguous 
respective planes. Also, that the operator may translate each of the 
plurality of members to any position within its respective plane so that 
the plurality of members of material can assume any one of a plurality of 
predetermined relative configurations. 
Clamp 38 is then lowered onto the tops of the sheets 42 by turning screw 
clamp 40 (FIG. 2). The sheets 42 are immovably locked into place in order 
that the above crown molding shape may be maintained during the cutting 
and sanding operation. 
The above discussion and drawings displays that the operator can immovably 
fix or clamp the plurality of members, which are sheets 42, in any one of 
a plurality of predetermined configurations. 
The sandpaper 78 is attached to the sanding surface section of sheets 42b 
(FIG. 6). This accomplished by starting the lamination at one side of the 
sanding surface which is created by the edges of the sheets, and moving 
across the face of the surface, pushing the adhesive-backed sandpaper onto 
the sheet edges. 
The above discussion and drawings displays that upon the fixing or clamping 
of the plurality of members in any one of the plurality of predetermined 
configurations, the members form a surface with a predetermined shape. 
The uniform lamination of the sandpaper is accomplished by its lamination 
to the sheet edges, one sheet at a time, by pushing the sandpaper onto the 
sheet edge by use of the edge of sandpaper application tool 79 (FIG. 6). 
The operator next loosens tightening knob 68 and rotates the apparatus to a 
45-degree angle, and then tightens the same (FIG. 3). This accomplishes 
the back cutting of the crown molding so that it will fit into a 90-degree 
corner. Alternatively, the operator may loosen knob 74 and tip the blade 
frame to the right or left to the desired angle, and then tighten the same 
(FIG. 5). 
If the cut to be done is at a compound angle, the operator may perform both 
of the above operations until the desired compound angle is achieved, thus 
displaying the tool's ability to easily and accurately cut shapes into 
materials within two and three dimensions. 
Next, clamp 51 is loosened and adjustable material support sheets 53 are 
moved into proximity to sheets 42 (FIGS. 1 and 4). Sheet clamp 51 is then 
tightened. To cope the crown molding at the end of its length, the 
following procedure is required: Rotating fences 14 are rotated to a 
position parallel with the plurality of stacking sheets 42 and locked into 
place by the tightening of rotating fence pivot tightening knobs 16 (FIG. 
1). The crown molding is placed upon material support surface 26 parallel 
to sheets 42. Screw clamps 15 are tightened upon the crown molding, making 
it immovable for the milling operation, thus displaying the tool's ability 
to cut and sand the material while the material is immovably clamped on a 
horizontal surface. 
At this time the cutting of the crown molding is ready to commence. Motor 
switch 12a (FIG. 1) is turned on, causing the blade frame and blades to 
recipricate. Reciprocal (linear) motion is created from the motors rotary 
motion by the following means: crankshaft 52a rotates in a circular motion 
about the centerline of speed reducer shaft 45. Offset shaft 52c rotates 
in a circle about the center of crankshaft 52a. Crank rod 52b is attached 
to offset shaft 52c. Upon the rotation of offset shaft 52c crank rod 52b 
moves in a reciprocal (linear) motion. Rod 52b is attached to shaft and 
shaft hangers 55b. Shaft and shaft hangers 55b are attached to blade frame 
36. This is the phase in which only the sawtoothed section of blades 42a 
are recipricated adjacent to table 26. Handle 10 is then pulled with slow 
even pressure into the clamped crown molding for cutting. When the cut is 
completed, handle 10 is pushed away, causing the blades to disengage from 
the crown molding being cut. 
At this time the sanding of the crown molding is ready to commence. Switch 
12b (FIG. 1) is turned to the "up" position and the blades and blade frame 
36 are lifted up to recipricate in the sanding area 94 (FIG. 8). This is 
the area in which only the sanding blade section of sheets 42b are 
recipricated adjacent to table 26. Handles 10 (FIG. 1) are then pulled 
with slow even pressure into the clamped material for sanding. When the 
sanding is completed, handle 10 is pushed back into its original position 
and switch 12b is turned to the "down" position until the blades and blade 
frame return to their original position. The above discussion and drawings 
show the tool's ability to achieve the cutting and sanding of complex 
shapes with a simple straight-line blade manipulation. The above 
discussion and drawings also show the tool's ability to leave a smoothly 
sanded surface after the cutting of the material to the desired shape. 
Switch 12a is then turned off. The cutting and sanding of the shape is 
complete. 
The above discussion and drawings displays the apparatus ability to 
reciprocate the plurality of members of material, which are sheets 42, so 
that when the plurality of members of material and a body of material 17 
are engaged, the body of material 17 is shaped to a shape which matches 
the predetermined shape created by the plurality of members of material. 
Alternatively, should the operator wish to form the exact negative of the 
above profile, the above steps may be followed with the material placed on 
the opposite side of the material support surface (FIG. 1). The opposite 
side of sheets 42 are brought into contact with the crown molding. 
The above discussion and drawings displays the tool's ability to achieve 
the simultaneous setup of both the positive profile and the negative of 
that profile. Additionally, at the same time is achieved the simultaneous 
setup of both the cutting and sanding profile shapes in both positive and 
negative profiles. 
Additionally, the above discussion and drawings show the tool's ability to 
cut and sand both the original shape and the negative of the original 
shape with only one setup operation. 
The above discussion and drawings also shows that the tool requires minimal 
skill to operate, yet can provide repetitive, high-tolerance shape cutting 
and sanding with zero margin of error between the cutting profile shape 
and the sanding profile shape. 
Summary, Ramifications, and Scope 
Thus the reader will see that the coping and profile cutting and/or sanding 
apparatus of the invention provides a highly versatile, time saving, 
precision cutting and sanding device that can be used by persons of almost 
any skill level. 
The apparatus can easily cut and sand shapes into the sides, top, bottom, 
or ends of a variety of materials. Additionally, the operator quickly and 
simultaneously adjusts the sheets of material to the desired profiles. The 
apparatus accurately cuts shapes into materials in two and three 
dimensions, leaving a smoothly sanded surface after cutting the material 
into the desired shape. 
The ease of material handling to perform the cutting and sanding operations 
of complex shapes is the result of first immovably clamping the material 
to the horizontal material support surface and then performing the cutting 
and sanding operation by simple straight-line blade manipulation. 
The plurality of sheets of material are easily adjusted to any profile and 
automatically yields the negative of the original profile. These above 
sheets of material, when clamped immovably for the cutting and sanding 
operation, yield a repetitive high tolerance profile cutting and sanding 
tool with zero margin of error between the cutting profile and the sanding 
profile. 
While the above description contains many specificities, these should not 
be construed as limitations on the scope of the invention, but rather as 
an exemplification of one preferred embodiment thereof. 
Other embodiments may be used or modifications and additions may be made to 
the described embodiment for performing within the scope of the present 
invention. For example: 
(a) Multiple stacks of sheets of material may be combined in the same tool 
to execute multiple shape set-ups, performing cutting and sanding 
operations from multiple directions. 
(b) The apparatus can be made at any size, from microscopic to heavy 
industrial. 
(c) The sheets and adhesive-backed abrasives can be made of any material 
and design appropriate to the material which is to be cut. 
(d) The sheets of material shape can be altered in a variety of ways 
appropriate to the use of the apparatus. 
(e) The parts of the apparatus can be connected or associated with their 
adjacent parts in a variety of ways, e.g., the motor can be placed above 
the stacking sheets of material instead of below; the sanding surface may 
be placed above the cutting surface instead of below, etc. 
(f) The control and drive components may be modified in a variety of ways, 
e.g., by human powered mechanical devices, hydraulics, pneumatics, etc. 
(g) The apparatus can be made separately as only a stationary cutting tool 
or only a stationary sanding tool. It can also be used as a hand-held 
power tool of combined or separate function and as a non-power hand tool 
of combined or separate functions. 
(h) The sanding section of the sheets of material may be modified for the 
sanding of extremely precise shapes. This may be accomplished by filling 
the voids between the sheets with a bonding, yet removable material. The 
material may be applied by the "screeding" of this material along the 
"high points" that exist after the thin square edged sheets are adjusted. 
In another approach a flexible, yet rigid adhesive-backed sheet of material 
is adhered to the same "high point". 
(i) The material with abrasive edges which is used for the cutting and 
sanding operation may be made of shapes other than sheets, eg. abrasive 
wires which are strung top and bottom on moveable support shets, etc. 
(j) This technology can be utilized in the creation of sanding attachments 
or cutting attachments which can be attached to existing machinery such as 
recipricating saw, in line profile sanders, etc. 
(k) The saw teeth may be made in such a way as to attach to the edges of 
the sheets so that when the teeth become dull they may be disposed of and 
replaced with sharp saw teeth. 
Therefore, the present invention should not be limited to any single 
embodiment, but rather construed in breadth and scope in accordance with 
the appended claims in their legal equivalents.