Hand made Infill plane (woodwork)
- Thread starter famas
- Start date
With all the hard work that's gone into the plane so far I thought it would be a good idea to make a box for it to live in.
I Didn't want any thing too traditional looking. I wanted something with a modern twist so people are unaware of whats inside.
I had an image in my mind which involved an irregular octagon, and with that I set about making it.
I started by Ripping up some Birch plywood to the required dimensions.
Next I set up a spindle moulder to 22.5 degrees and ran the edges of the plywood through.
I then trimmed the plywood to length and used masking tape to join all the pieces together.
I applied a healthy amount of glue to the joints
And used the masking tape to hold it all together.
Finally I add ratchet straps to pull the joints up tight.
I cleaned off any surplus glue with a damp cloth and left it to dry overnight ready for the next stage tomorrow.
I Didn't want any thing too traditional looking. I wanted something with a modern twist so people are unaware of whats inside.
I had an image in my mind which involved an irregular octagon, and with that I set about making it.
I started by Ripping up some Birch plywood to the required dimensions.
Next I set up a spindle moulder to 22.5 degrees and ran the edges of the plywood through.
I then trimmed the plywood to length and used masking tape to join all the pieces together.
I applied a healthy amount of glue to the joints
And used the masking tape to hold it all together.
Finally I add ratchet straps to pull the joints up tight.
I cleaned off any surplus glue with a damp cloth and left it to dry overnight ready for the next stage tomorrow.
With the outside of the box made I started work on the plane holder.
The plane will be secured in the holder and the holder will slide in and out of the box.
First I cut out and shaped the sides.
Then rounded over the edges on the router.
I cut out the bottom and front for the holder.
I then cut a dovetailed groove on the under side of the bottom, then glued the bottom and front to the sides.
While that was drying I cut out some guides that are the same shape as the ends of the plane.
I then glued the guides to the bottom of the holder. The plane sits tightly between them.
Next I cut and fitted the front and back of the box. The back will get glued in place to the box while the front will be fixed to the holder.
Here you can see how the holder slides into the box.
I fixed a dovetailed rail to the bottom of the box that corresponds to the groove on the underside of the holder.
Lastly I set up the spindle at 45 degrees and ran a chamfer around the ends of the box.
All that's left to do now is sand it up ready for paint.
The plane will be secured in the holder and the holder will slide in and out of the box.
First I cut out and shaped the sides.
Then rounded over the edges on the router.
I cut out the bottom and front for the holder.
I then cut a dovetailed groove on the under side of the bottom, then glued the bottom and front to the sides.
While that was drying I cut out some guides that are the same shape as the ends of the plane.
I then glued the guides to the bottom of the holder. The plane sits tightly between them.
Next I cut and fitted the front and back of the box. The back will get glued in place to the box while the front will be fixed to the holder.
Here you can see how the holder slides into the box.
I fixed a dovetailed rail to the bottom of the box that corresponds to the groove on the underside of the holder.
Lastly I set up the spindle at 45 degrees and ran a chamfer around the ends of the box.
All that's left to do now is sand it up ready for paint.
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Thanks for the comment Lucky.
Some years ago I did a 3 year apprenticeship under the guidance of a reproduction furniture maker of over 35 years. 18 years later we are both still working together.
I'm lucky that where we work I see a job through from start to finish, from preparing timber from rough sawn logs to manufacture of the item and lastly onto finish.
There's no "production line" or exchanging of jobs from one procedure to the next, every stage is done by one individual.
It's nice that we're not making the same thing day in day out, every item is unique and bespoke.
Funny you mention guitars, a guy that used to work with use was into playing the electric guitar and made one for himself.
I have thought about making a wooden tongue drum several times, think I should start there before attempting a guitar
I needed a way to lock the box so came up with a simple latch solution.
I started by cutting a piece of steel flat bar and inserting a small length of brass rod which I had cut a thread onto one end.
The brass rod fits through a hole in the front of the box.
With my last bit of brass I machined a round handle and threaded the centre of it to fit onto the brass rod.
I also made the catch out of another piece of steel flat bar.
I filed a small bevel on the front of the catch, it then gets screwed to the inside of the box.
Ignore the screws sitting proud, this was just a test fit.
Next I cut the lever to length and filed a corresponding bevel to the under side, I also cut a slot for a spring to hook onto.
With the front of the box fixed to the plane holder the lever can be inserted and the spring fixed to it.
Twisting the brass handle on the front of the box raises the lever, the spring then pulls it back down.
The bevels on the lever and catch are to let the lever rise and full into the notch in the catch with out any input needed on the handle.
This means the box will lock on it's own when the holder is pushed shut.
Lastly I added a small steel key pin to the brass rod to stop it spinning in it's hole.
And finally gave every thing a sand and polish.
Some years ago I did a 3 year apprenticeship under the guidance of a reproduction furniture maker of over 35 years. 18 years later we are both still working together.
I'm lucky that where we work I see a job through from start to finish, from preparing timber from rough sawn logs to manufacture of the item and lastly onto finish.
There's no "production line" or exchanging of jobs from one procedure to the next, every stage is done by one individual.
It's nice that we're not making the same thing day in day out, every item is unique and bespoke.
Funny you mention guitars, a guy that used to work with use was into playing the electric guitar and made one for himself.
I have thought about making a wooden tongue drum several times, think I should start there before attempting a guitar
I needed a way to lock the box so came up with a simple latch solution.
I started by cutting a piece of steel flat bar and inserting a small length of brass rod which I had cut a thread onto one end.
The brass rod fits through a hole in the front of the box.
With my last bit of brass I machined a round handle and threaded the centre of it to fit onto the brass rod.
I also made the catch out of another piece of steel flat bar.
I filed a small bevel on the front of the catch, it then gets screwed to the inside of the box.
Ignore the screws sitting proud, this was just a test fit.
Next I cut the lever to length and filed a corresponding bevel to the under side, I also cut a slot for a spring to hook onto.
With the front of the box fixed to the plane holder the lever can be inserted and the spring fixed to it.
Twisting the brass handle on the front of the box raises the lever, the spring then pulls it back down.
The bevels on the lever and catch are to let the lever rise and full into the notch in the catch with out any input needed on the handle.
This means the box will lock on it's own when the holder is pushed shut.
Lastly I added a small steel key pin to the brass rod to stop it spinning in it's hole.
And finally gave every thing a sand and polish.
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Thanks for the comment Acme.
The basic hand skills for cutting and shaping metal are transferable from wood, I guess when machinery starts getting involved the difference become more apparent.
Engineering lathes are similar to wood lathes, spindle moulders and over head routers are similar to milling machines, the main consideration is understanding how the material you're working with behaves when cutting.
Metal only processes like peening, hardening, brazing and etching were all new to me. I did a load of research before attempting them, but having the experience from woodwork definitely helped to some degree.
The basic hand skills for cutting and shaping metal are transferable from wood, I guess when machinery starts getting involved the difference become more apparent.
Engineering lathes are similar to wood lathes, spindle moulders and over head routers are similar to milling machines, the main consideration is understanding how the material you're working with behaves when cutting.
Metal only processes like peening, hardening, brazing and etching were all new to me. I did a load of research before attempting them, but having the experience from woodwork definitely helped to some degree.
Now the latch is completed I could finish the box.
I fitted and glued the back of the box in place then sanded every thing to 500 grit.
The inside and slide of the box are going to be clear lacquered while the outside will be painted. I used masking tape and paper to cover the external of the box so as not to get lacquer on it.
Next I applied 4 coats of lacquer to the inside of the box and the slide.
Leaving 10 minutes between coats and lightly rubbing down with 1000 grit.
The wood burner was lit so drying time was quick.
Once the inside of the box was dry I removed the masking tape and paper.
I want the grain of the birch wood to show in the paint so I used a brass brush to open the grain.
I then applied 1 light coat of black paint.
I left 10 minutes before applying another coat.
2 coats was enough to cover the wood, I didn't want to apply to many coats as the paint will start to fill the grain.
I've still to lacquer the box but will do that once the paint has cured over night.
I took a few very short videos of some of the processes while making the plane which I've put together into one video.
Not massively interesting but some of you might like to see it.
https://www.youtube.com/watch?v=4mXhMrB7r2U
I fitted and glued the back of the box in place then sanded every thing to 500 grit.
The inside and slide of the box are going to be clear lacquered while the outside will be painted. I used masking tape and paper to cover the external of the box so as not to get lacquer on it.
Next I applied 4 coats of lacquer to the inside of the box and the slide.
Leaving 10 minutes between coats and lightly rubbing down with 1000 grit.
The wood burner was lit so drying time was quick.
Once the inside of the box was dry I removed the masking tape and paper.
I want the grain of the birch wood to show in the paint so I used a brass brush to open the grain.
I then applied 1 light coat of black paint.
I left 10 minutes before applying another coat.
2 coats was enough to cover the wood, I didn't want to apply to many coats as the paint will start to fill the grain.
I've still to lacquer the box but will do that once the paint has cured over night.
I took a few very short videos of some of the processes while making the plane which I've put together into one video.
Not massively interesting but some of you might like to see it.
https://www.youtube.com/watch?v=4mXhMrB7r2U
Thanks for the replies guys I appreciate your comments.
Hopefully the plane will stay with me for the rest of my career and more.
I've a mixture of genuine gen 1 and 2 batteries, the gen 1's are all but dead now.
I've also got a knock off 5Ah battery from e bay that was £30.
For the money the knock off has been great. Seems to have good power and lasts a lot longer than the genuine ones, though they are only 2Ah.
Think you have to be a bit careful which one you buy as some are better than others, it's pot luck what cells they use.
Mines a flag power, it seemed to get positive reviews so I went with it.
Hopefully the plane will stay with me for the rest of my career and more.
I've a mixture of genuine gen 1 and 2 batteries, the gen 1's are all but dead now.
I've also got a knock off 5Ah battery from e bay that was £30.
For the money the knock off has been great. Seems to have good power and lasts a lot longer than the genuine ones, though they are only 2Ah.
Think you have to be a bit careful which one you buy as some are better than others, it's pot luck what cells they use.
Mines a flag power, it seemed to get positive reviews so I went with it.
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With the black paint now dry I could start applying the lacquer.
I sprayed 3 coats of lacquer onto the box leaving 10 minutes between coats, no need to rub down this time.
Once the lacquer was dry I started to cut it back with wet and dry sand paper.
I sanded from 1200 to 2500 grit.
With the entire box sanded to 2500 grit I could start to polish it.
I'm using Farecla g10 finishing compound and a medium sponge buffing pad to bring back the initial shine.
Once I was happy with that stage I used super resin polish and a fine sponge pad to get a gloss finish.
Lastly I applied a coat of Dodo juice for a little extra shine and the sweet smell of Carnauba wax
With the paint work done I fitted the brass handle and lever catch to the front of the box.
I also added some Velcro strips to secure the plane in place when in the box.
Finally I cut and fitted foam to the inside of the box just for a little added protection.
Other than adding some rubber feet the box was complete.
I sprayed 3 coats of lacquer onto the box leaving 10 minutes between coats, no need to rub down this time.
Once the lacquer was dry I started to cut it back with wet and dry sand paper.
I sanded from 1200 to 2500 grit.
With the entire box sanded to 2500 grit I could start to polish it.
I'm using Farecla g10 finishing compound and a medium sponge buffing pad to bring back the initial shine.
Once I was happy with that stage I used super resin polish and a fine sponge pad to get a gloss finish.
Lastly I applied a coat of Dodo juice for a little extra shine and the sweet smell of Carnauba wax
With the paint work done I fitted the brass handle and lever catch to the front of the box.
I also added some Velcro strips to secure the plane in place when in the box.
Finally I cut and fitted foam to the inside of the box just for a little added protection.
Other than adding some rubber feet the box was complete.
With the box complete I could add the finishing touches to the plane.
I started by making the brass collar to go under the front knob, this was purely for aesthetics as I thought the transition from cherry wood to aluminium to brass looked nicer.
I forgot to take pictures of this but here it is fitted to the plane.
Finally the plane was complete. I took a few hours to clean and wax every part before reassembling.
When I started this project I didn't realise how far it would take me. I've learnt so much along the way, so many new skills and techniques that I can develop further.
I've probably gotten more enjoyment from making this plane than I will using it, (if I use it!)
Its been the combination of over 5 months in the making and roughly 180 hours work.
It's been quite the journey of late nights, hard work, concentration and constant nagging by the better half but I got there in the end.
I'd say I'm 90% happy with the end result, there are a few things which let it down but for a first attempt at a metal body plane it far exceeded my expectation.
I think it's important to constructively critique your own work and people have told me I'm my own worst enemy but the day I make something that's perfect is the day I've lost myself.
Thank you for all of the messages along the way, I really appreciate every one.
They say a picture is worth a thousand words so I'll stop my rambling now and just show the finished plane, there's a lot of pictures!
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I've also done a quick video demonstrating the plane.
https://youtu.be/eAc3UonpC60
I hope you've enjoyed following the project as much as I have making it.
I started by making the brass collar to go under the front knob, this was purely for aesthetics as I thought the transition from cherry wood to aluminium to brass looked nicer.
I forgot to take pictures of this but here it is fitted to the plane.
Finally the plane was complete. I took a few hours to clean and wax every part before reassembling.
When I started this project I didn't realise how far it would take me. I've learnt so much along the way, so many new skills and techniques that I can develop further.
I've probably gotten more enjoyment from making this plane than I will using it, (if I use it!)
Its been the combination of over 5 months in the making and roughly 180 hours work.
It's been quite the journey of late nights, hard work, concentration and constant nagging by the better half but I got there in the end.
I'd say I'm 90% happy with the end result, there are a few things which let it down but for a first attempt at a metal body plane it far exceeded my expectation.
I think it's important to constructively critique your own work and people have told me I'm my own worst enemy but the day I make something that's perfect is the day I've lost myself.
Thank you for all of the messages along the way, I really appreciate every one.
They say a picture is worth a thousand words so I'll stop my rambling now and just show the finished plane, there's a lot of pictures!
1
2
3
4
5
6
7
8
9
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10
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18
19
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20
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23
24
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28
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30
31
32
33
34
I've also done a quick video demonstrating the plane.
https://youtu.be/eAc3UonpC60
I hope you've enjoyed following the project as much as I have making it.
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Thanks for the comment guys
I suspect I'll make another plane at some point, I'm in need of a decent shoulder plane so that might be next.
I have thought about vlogging but it's a lot of extra work, taking pictures is quick and easy but setting up a camera and filming every stage would be difficult not to mention the extra time in processing all the footage.
I don't have a decent camera either, I did the video for this one on my phone and even that took a good few hours to process.
We'll see, I might give it a go for the next one, won't be any time soon though.
I suspect I'll make another plane at some point, I'm in need of a decent shoulder plane so that might be next.
I have thought about vlogging but it's a lot of extra work, taking pictures is quick and easy but setting up a camera and filming every stage would be difficult not to mention the extra time in processing all the footage.
I don't have a decent camera either, I did the video for this one on my phone and even that took a good few hours to process.
We'll see, I might give it a go for the next one, won't be any time soon though.
I'll probably just add on to this thread, keeps every thing in one place as it's another plane.
Not sure If I'll update as frequently as the last project. I'm trying to do more video but I cant stand the sound of my own voice, I sound like a breaking down robot
I'm going very traditional this time with a English mitre plane. As far as I'm aware there were no set sizes for them, they range from block plane size up to jack plane size.
I was given the piece of brass so had to make it fit that, It should end up a little bigger than a block plane.
While they look very simple in design they are difficult planes to make as the sole fits from the bottom onto the sides and the main feature is the extremely tight mouth, meaning the sole is made from 2 pieces perfectly aligned and fitted together. It will certainly test my abilities that's for sure.
I was planning to make a different plane all together but I've no spare cash at the moment and the materials for it are quite costly.
I'll see how this one goes, I might make it after.
I must have had the flag power for about 3 years now with no problems.
Finally finished the bridge.
I'm really pleased with how it turned out. I can start to assemble the body of the plane now.
I've still got the sole of the plane to make yet and there is a lot of work involved with that, even more so than the body.
I'm really pleased with how it turned out. I can start to assemble the body of the plane now.
I've still got the sole of the plane to make yet and there is a lot of work involved with that, even more so than the body.
I've started work on the sole and its tough going!
These are the initial cuts that start to form the mouth. There was a lot of filing involved after.
Here you can see the sole is made from two pieces of steel with the mouth cut into the left hand piece and the relief cut onto the right hand piece.
There is also a V joint which aligns both pieces together.
Doesn't look much but there was a lot of work involved.
These are the initial cuts that start to form the mouth. There was a lot of filing involved after.
Here you can see the sole is made from two pieces of steel with the mouth cut into the left hand piece and the relief cut onto the right hand piece.
There is also a V joint which aligns both pieces together.
Doesn't look much but there was a lot of work involved.