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5K views 24 replies 9 participants last post by  MikeB_UK 
#1 ·
Low angle beech router

Well, not so much low as low for a traditional router plane.

Traditional high angle router planes are great for final clean-up of a grove or dado, but sometimes you want one that takes off more stock.
For that you need a lower angle on the blade, something more like a standard plane, so about 45 degrees.

First thought was grab a likely looking piece of beech.
However, I've got nothing thick enough so I'll have cut to length and glue it up.
Wood Table Rectangle Floor Wood stain

Hand tool Wood Tool Metalworking hand tool Gas

Blue Wood Tool Gas Hardwood


Square it up and plane 45(ish) degree chamfer.
You don't need to do this, but I find it easier to drill the hole at 90 degrees to the face
Wood Flooring Hardwood Lumber Wood stain

Table Wood Flooring Hardwood Wood stain


Drill a hole, just eyeball it, doesn't need to be perfect.
Wood Flooring Floor Wood stain Hardwood

Wood Tool Metalworking hand tool Hand tool Hardwood


Square it out and angle it with a chisel and rasp.
Wood Wood stain Floor Flooring Hardwood


Test fit.
Wood Natural material Hardwood Wood stain Building material


Keep taking bits off until it fits tightly at both ends.
It's at this point that I realised that working out the angles I needed to end up with would have made this much simpler.
I could have altered the wedge angle, but figured it would be better to change the hole.
Wood Flooring Floor Wood stain Rectangle

And that's a working router plane, everything from this point on is removing stock for comfort, grip, looks & ease of use.

Time to shape it.
Wood Flooring Floor Wood stain Hardwood

Wood Composite material Engineering Building material Hardwood


Add some curves.
Flower Wood Window Plant Petal

Wood Tool Hardwood Font Metal

Wood Rectangle Flooring Floor Wood stain


Cut a slot so you can see the blade.
And done.
Wood Natural material Floor Wood stain Flooring


OK, after testing it needed a few changes, the grip was digging into my palms a bit and I couldn't see what was happening if I was planning away from me.
So needed some adjustment.
Easy enough to sort, use a rasp to fix the grip by smoothing the spots where it was digging in.
Wood Floor Rectangle Hardwood Flooring


And use a rasp to enlarge the place to view the blade so it can be seen from directly above.
Wood Wood stain Hardwood Tool Hand tool

Wood Hardwood Art Wood stain Plywood


And that works, I think the next one needs a bit more width and depth, this one ended up just a little small for my hands.
 

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#2 ·
Low angle beech router

Well, not so much low as low for a traditional router plane.

Traditional high angle router planes are great for final clean-up of a grove or dado, but sometimes you want one that takes off more stock.
For that you need a lower angle on the blade, something more like a standard plane, so about 45 degrees.

First thought was grab a likely looking piece of beech.
However, I've got nothing thick enough so I'll have cut to length and glue it up.
Wood Table Rectangle Floor Wood stain

Hand tool Wood Tool Metalworking hand tool Gas

Blue Wood Tool Gas Hardwood


Square it up and plane 45(ish) degree chamfer.
You don't need to do this, but I find it easier to drill the hole at 90 degrees to the face
Wood Flooring Hardwood Lumber Wood stain

Table Wood Flooring Hardwood Wood stain


Drill a hole, just eyeball it, doesn't need to be perfect.
Wood Flooring Floor Wood stain Hardwood

Wood Tool Metalworking hand tool Hand tool Hardwood


Square it out and angle it with a chisel and rasp.
Wood Wood stain Floor Flooring Hardwood


Test fit.
Wood Natural material Hardwood Wood stain Building material


Keep taking bits off until it fits tightly at both ends.
It's at this point that I realised that working out the angles I needed to end up with would have made this much simpler.
I could have altered the wedge angle, but figured it would be better to change the hole.
Wood Flooring Floor Wood stain Rectangle

And that's a working router plane, everything from this point on is removing stock for comfort, grip, looks & ease of use.

Time to shape it.
Wood Flooring Floor Wood stain Hardwood

Wood Composite material Engineering Building material Hardwood


Add some curves.
Flower Wood Window Plant Petal

Wood Tool Hardwood Font Metal

Wood Rectangle Flooring Floor Wood stain


Cut a slot so you can see the blade.
And done.
Wood Natural material Floor Wood stain Flooring


OK, after testing it needed a few changes, the grip was digging into my palms a bit and I couldn't see what was happening if I was planning away from me.
So needed some adjustment.
Easy enough to sort, use a rasp to fix the grip by smoothing the spots where it was digging in.
Wood Floor Rectangle Hardwood Flooring


And use a rasp to enlarge the place to view the blade so it can be seen from directly above.
Wood Wood stain Hardwood Tool Hand tool

Wood Hardwood Art Wood stain Plywood


And that works, I think the next one needs a bit more width and depth, this one ended up just a little small for my hands.
That looks like it'll do the job, Mike.
 

Attachments

#3 ·
Low angle beech router

Well, not so much low as low for a traditional router plane.

Traditional high angle router planes are great for final clean-up of a grove or dado, but sometimes you want one that takes off more stock.
For that you need a lower angle on the blade, something more like a standard plane, so about 45 degrees.

First thought was grab a likely looking piece of beech.
However, I've got nothing thick enough so I'll have cut to length and glue it up.
Wood Table Rectangle Floor Wood stain

Hand tool Wood Tool Metalworking hand tool Gas

Blue Wood Tool Gas Hardwood


Square it up and plane 45(ish) degree chamfer.
You don't need to do this, but I find it easier to drill the hole at 90 degrees to the face
Wood Flooring Hardwood Lumber Wood stain

Table Wood Flooring Hardwood Wood stain


Drill a hole, just eyeball it, doesn't need to be perfect.
Wood Flooring Floor Wood stain Hardwood

Wood Tool Metalworking hand tool Hand tool Hardwood


Square it out and angle it with a chisel and rasp.
Wood Wood stain Floor Flooring Hardwood


Test fit.
Wood Natural material Hardwood Wood stain Building material


Keep taking bits off until it fits tightly at both ends.
It's at this point that I realised that working out the angles I needed to end up with would have made this much simpler.
I could have altered the wedge angle, but figured it would be better to change the hole.
Wood Flooring Floor Wood stain Rectangle

And that's a working router plane, everything from this point on is removing stock for comfort, grip, looks & ease of use.

Time to shape it.
Wood Flooring Floor Wood stain Hardwood

Wood Composite material Engineering Building material Hardwood


Add some curves.
Flower Wood Window Plant Petal

Wood Tool Hardwood Font Metal

Wood Rectangle Flooring Floor Wood stain


Cut a slot so you can see the blade.
And done.
Wood Natural material Floor Wood stain Flooring


OK, after testing it needed a few changes, the grip was digging into my palms a bit and I couldn't see what was happening if I was planning away from me.
So needed some adjustment.
Easy enough to sort, use a rasp to fix the grip by smoothing the spots where it was digging in.
Wood Floor Rectangle Hardwood Flooring


And use a rasp to enlarge the place to view the blade so it can be seen from directly above.
Wood Wood stain Hardwood Tool Hand tool

Wood Hardwood Art Wood stain Plywood


And that works, I think the next one needs a bit more width and depth, this one ended up just a little small for my hands.
Yeah, the lower than traditional angle makes it pretty good for trimming tennons as well.

This one is firmly in the it'll do for now, but build a new one later pile, definitely needs a bit more bulk and width before it's right, I'll keep using it and figure out what I want to end up with, I'm edging toward something a bit more spokeshave shaped, at least for grooves and dados.
I suspect I'll end up with a few different ones tailored toward different functions.
 

Attachments

#4 ·
Low angle beech router

Well, not so much low as low for a traditional router plane.

Traditional high angle router planes are great for final clean-up of a grove or dado, but sometimes you want one that takes off more stock.
For that you need a lower angle on the blade, something more like a standard plane, so about 45 degrees.

First thought was grab a likely looking piece of beech.
However, I've got nothing thick enough so I'll have cut to length and glue it up.
Wood Table Rectangle Floor Wood stain

Hand tool Wood Tool Metalworking hand tool Gas

Blue Wood Tool Gas Hardwood


Square it up and plane 45(ish) degree chamfer.
You don't need to do this, but I find it easier to drill the hole at 90 degrees to the face
Wood Flooring Hardwood Lumber Wood stain

Table Wood Flooring Hardwood Wood stain


Drill a hole, just eyeball it, doesn't need to be perfect.
Wood Flooring Floor Wood stain Hardwood

Wood Tool Metalworking hand tool Hand tool Hardwood


Square it out and angle it with a chisel and rasp.
Wood Wood stain Floor Flooring Hardwood


Test fit.
Wood Natural material Hardwood Wood stain Building material


Keep taking bits off until it fits tightly at both ends.
It's at this point that I realised that working out the angles I needed to end up with would have made this much simpler.
I could have altered the wedge angle, but figured it would be better to change the hole.
Wood Flooring Floor Wood stain Rectangle

And that's a working router plane, everything from this point on is removing stock for comfort, grip, looks & ease of use.

Time to shape it.
Wood Flooring Floor Wood stain Hardwood

Wood Composite material Engineering Building material Hardwood


Add some curves.
Flower Wood Window Plant Petal

Wood Tool Hardwood Font Metal

Wood Rectangle Flooring Floor Wood stain


Cut a slot so you can see the blade.
And done.
Wood Natural material Floor Wood stain Flooring


OK, after testing it needed a few changes, the grip was digging into my palms a bit and I couldn't see what was happening if I was planning away from me.
So needed some adjustment.
Easy enough to sort, use a rasp to fix the grip by smoothing the spots where it was digging in.
Wood Floor Rectangle Hardwood Flooring


And use a rasp to enlarge the place to view the blade so it can be seen from directly above.
Wood Wood stain Hardwood Tool Hand tool

Wood Hardwood Art Wood stain Plywood


And that works, I think the next one needs a bit more width and depth, this one ended up just a little small for my hands.
"A few tailored toward different functions," will be the title of my autobiography, I've just decided.

I can't think of any tool I've built for my shop where I stopped with just one, whether the second was one for someone else in a swap, or one with a few small improvements I thought of over time, or one to do a different job… I suspect I have more fun building tools than I do building projects and some day I'll admit that and quit building projects entirely, but for now there's too long of a list…
 

Attachments

#5 ·
Low angle beech router

Well, not so much low as low for a traditional router plane.

Traditional high angle router planes are great for final clean-up of a grove or dado, but sometimes you want one that takes off more stock.
For that you need a lower angle on the blade, something more like a standard plane, so about 45 degrees.

First thought was grab a likely looking piece of beech.
However, I've got nothing thick enough so I'll have cut to length and glue it up.
Wood Table Rectangle Floor Wood stain

Hand tool Wood Tool Metalworking hand tool Gas

Blue Wood Tool Gas Hardwood


Square it up and plane 45(ish) degree chamfer.
You don't need to do this, but I find it easier to drill the hole at 90 degrees to the face
Wood Flooring Hardwood Lumber Wood stain

Table Wood Flooring Hardwood Wood stain


Drill a hole, just eyeball it, doesn't need to be perfect.
Wood Flooring Floor Wood stain Hardwood

Wood Tool Metalworking hand tool Hand tool Hardwood


Square it out and angle it with a chisel and rasp.
Wood Wood stain Floor Flooring Hardwood


Test fit.
Wood Natural material Hardwood Wood stain Building material


Keep taking bits off until it fits tightly at both ends.
It's at this point that I realised that working out the angles I needed to end up with would have made this much simpler.
I could have altered the wedge angle, but figured it would be better to change the hole.
Wood Flooring Floor Wood stain Rectangle

And that's a working router plane, everything from this point on is removing stock for comfort, grip, looks & ease of use.

Time to shape it.
Wood Flooring Floor Wood stain Hardwood

Wood Composite material Engineering Building material Hardwood


Add some curves.
Flower Wood Window Plant Petal

Wood Tool Hardwood Font Metal

Wood Rectangle Flooring Floor Wood stain


Cut a slot so you can see the blade.
And done.
Wood Natural material Floor Wood stain Flooring


OK, after testing it needed a few changes, the grip was digging into my palms a bit and I couldn't see what was happening if I was planning away from me.
So needed some adjustment.
Easy enough to sort, use a rasp to fix the grip by smoothing the spots where it was digging in.
Wood Floor Rectangle Hardwood Flooring


And use a rasp to enlarge the place to view the blade so it can be seen from directly above.
Wood Wood stain Hardwood Tool Hand tool

Wood Hardwood Art Wood stain Plywood


And that works, I think the next one needs a bit more width and depth, this one ended up just a little small for my hands.
Try explaining to your sweetie that you've bought all those tools just so you can make tools, where do you want us to send the flowers? :)
I've managed to convince mine that I'll build something she wants then something I want.

The other reason I end up making a bunch of some things is, due to the vagarities of the internet, it's sometimes cheaper to buy a bunch of stuff instead of just one.

I'm going to have to build another 6 spokeshaves just so it doesn't look like I'm hording blades (1 iron on it's own was more expensive than this bunch.
Wood Hardwood Varnish Wood stain Plank
 

Attachments

#6 ·
Low angle beech router

Well, not so much low as low for a traditional router plane.

Traditional high angle router planes are great for final clean-up of a grove or dado, but sometimes you want one that takes off more stock.
For that you need a lower angle on the blade, something more like a standard plane, so about 45 degrees.

First thought was grab a likely looking piece of beech.
However, I've got nothing thick enough so I'll have cut to length and glue it up.
Wood Table Rectangle Floor Wood stain

Hand tool Wood Tool Metalworking hand tool Gas

Blue Wood Tool Gas Hardwood


Square it up and plane 45(ish) degree chamfer.
You don't need to do this, but I find it easier to drill the hole at 90 degrees to the face
Wood Flooring Hardwood Lumber Wood stain

Table Wood Flooring Hardwood Wood stain


Drill a hole, just eyeball it, doesn't need to be perfect.
Wood Flooring Floor Wood stain Hardwood

Wood Tool Metalworking hand tool Hand tool Hardwood


Square it out and angle it with a chisel and rasp.
Wood Wood stain Floor Flooring Hardwood


Test fit.
Wood Natural material Hardwood Wood stain Building material


Keep taking bits off until it fits tightly at both ends.
It's at this point that I realised that working out the angles I needed to end up with would have made this much simpler.
I could have altered the wedge angle, but figured it would be better to change the hole.
Wood Flooring Floor Wood stain Rectangle

And that's a working router plane, everything from this point on is removing stock for comfort, grip, looks & ease of use.

Time to shape it.
Wood Flooring Floor Wood stain Hardwood

Wood Composite material Engineering Building material Hardwood


Add some curves.
Flower Wood Window Plant Petal

Wood Tool Hardwood Font Metal

Wood Rectangle Flooring Floor Wood stain


Cut a slot so you can see the blade.
And done.
Wood Natural material Floor Wood stain Flooring


OK, after testing it needed a few changes, the grip was digging into my palms a bit and I couldn't see what was happening if I was planning away from me.
So needed some adjustment.
Easy enough to sort, use a rasp to fix the grip by smoothing the spots where it was digging in.
Wood Floor Rectangle Hardwood Flooring


And use a rasp to enlarge the place to view the blade so it can be seen from directly above.
Wood Wood stain Hardwood Tool Hand tool

Wood Hardwood Art Wood stain Plywood


And that works, I think the next one needs a bit more width and depth, this one ended up just a little small for my hands.
Yeah, that's part of it, Mike. As long as I'm producing things that are useful around the house (like bookcases ) or which make good gifts for neighbors who have helped us get settled (like bowls but not for much longer, I suspect), I have an excuse for making or acquiring tools.

And yes, the "it's cheaper to buy a half-dozen than it is to buy one" often leads to batch production… have I told you about the Stanley Global planes I found on eBay and have bought a few of, since they're cheap enough (and used to be even cheaper) that they make good donors or conversions to scrub planes or…
 

Attachments

#7 ·
Spalted Birch Router Plane

Going with a traditional hag's tooth design, so iron is at a high angle, works closer to a scraper than a plane. Just used for the final finish after a chisel.

Grab a likely looking chunk of wood, spalted birch in this case.
The log behind is elder if this goes wrong :)
Wood Ingredient Table Hardwood Wood stain


Clean it up to more or less the right shape.
Wood Metal Event Soil History


Wood Hardwood Natural material Building material Plank

Couple of suspicious looking cracks, so I'll have to split it off there as well.

Work out the angle for the iron, doesn't need to be too scientific, plough planes have a lot of tolerance for different angles.
Wood Vise Tool Hardwood Flooring


Drill a pilot hole to get the angle right.
Wood Tool Machine Engineering Auto part


Square it up with a chisel, then extend the top to create the wedge angle.
Wood Bumper Flooring Hardwood Table


Table Wood Wood stain Floor Workbench


Create the wedge from the bit I had to split off earlier.
Brown Wood Flooring Hardwood Wood stain

Wood Food Hardwood Font Cuisine


Fine tune the shape and angle of the wedge, just a trial and error, fit and trim.
Wood Natural material Hardwood Wood stain Hand tool


And it works, it's a bit longer on one side, you can't see what your cutting and it's really uncomfortable, but it does work.
Wood Wood stain Hardwood Flooring Rectangle


So now it's just basically :- remove bits to make the grip comfortable and remove a section at the front so you can see what's going on at the pointy end.
Wood Hand tool Wood stain Hardwood Plank


Time to break out the moulding planes (You can tell I don't make any big mouldings)
Wood Table Wood stain Hardwood Flooring


That went better than I expected to be honest, I thought I was going to have to blend in the edges with a gouge but it's fine as it is.
Wood Floor Wood stain Hardwood Flooring


This spalted birch is a bit soft, so add a plate to the bottom.
Wood Rectangle Flooring Floor Wood stain

You can either measure everything to position the screws or just square off some lines and connect the corners, no prizes for guessing which way I went.
Wood Rectangle Flooring Wood stain Triangle

Broke my drill bit, but carry on regardless
Wood Flooring Floor Wood stain Hardwood


Clock it in for all you retentives out there.
Wood Wood stain Varnish Hardwood Table


Wood Wood stain Hardwood Composite material Plank


And file for final fit, slowly, really slowly, I need to get some rougher files.
Wood Wood stain Rectangle Floor Natural material

Wood Hardwood Wood stain Metal Composite material


Smooth off the edges of everything and flatten the bottom.
Wood Wood stain Hardwood Composite material Plank


And finish, going with a varnish to add a bit of protection to the birch.
Wax up and I'm done.
Wood Wood stain Hardwood Plank Natural material


Works great
Wood Flooring Floor Wood stain Hardwood
 

Attachments

#8 ·
Spalted Birch Router Plane

Going with a traditional hag's tooth design, so iron is at a high angle, works closer to a scraper than a plane. Just used for the final finish after a chisel.

Grab a likely looking chunk of wood, spalted birch in this case.
The log behind is elder if this goes wrong :)
Wood Ingredient Table Hardwood Wood stain


Clean it up to more or less the right shape.
Wood Metal Event Soil History


Wood Hardwood Natural material Building material Plank

Couple of suspicious looking cracks, so I'll have to split it off there as well.

Work out the angle for the iron, doesn't need to be too scientific, plough planes have a lot of tolerance for different angles.
Wood Vise Tool Hardwood Flooring


Drill a pilot hole to get the angle right.
Wood Tool Machine Engineering Auto part


Square it up with a chisel, then extend the top to create the wedge angle.
Wood Bumper Flooring Hardwood Table


Table Wood Wood stain Floor Workbench


Create the wedge from the bit I had to split off earlier.
Brown Wood Flooring Hardwood Wood stain

Wood Food Hardwood Font Cuisine


Fine tune the shape and angle of the wedge, just a trial and error, fit and trim.
Wood Natural material Hardwood Wood stain Hand tool


And it works, it's a bit longer on one side, you can't see what your cutting and it's really uncomfortable, but it does work.
Wood Wood stain Hardwood Flooring Rectangle


So now it's just basically :- remove bits to make the grip comfortable and remove a section at the front so you can see what's going on at the pointy end.
Wood Hand tool Wood stain Hardwood Plank


Time to break out the moulding planes (You can tell I don't make any big mouldings)
Wood Table Wood stain Hardwood Flooring


That went better than I expected to be honest, I thought I was going to have to blend in the edges with a gouge but it's fine as it is.
Wood Floor Wood stain Hardwood Flooring


This spalted birch is a bit soft, so add a plate to the bottom.
Wood Rectangle Flooring Floor Wood stain

You can either measure everything to position the screws or just square off some lines and connect the corners, no prizes for guessing which way I went.
Wood Rectangle Flooring Wood stain Triangle

Broke my drill bit, but carry on regardless
Wood Flooring Floor Wood stain Hardwood


Clock it in for all you retentives out there.
Wood Wood stain Varnish Hardwood Table


Wood Wood stain Hardwood Composite material Plank


And file for final fit, slowly, really slowly, I need to get some rougher files.
Wood Wood stain Rectangle Floor Natural material

Wood Hardwood Wood stain Metal Composite material


Smooth off the edges of everything and flatten the bottom.
Wood Wood stain Hardwood Composite material Plank


And finish, going with a varnish to add a bit of protection to the birch.
Wax up and I'm done.
Wood Wood stain Hardwood Plank Natural material


Works great
Wood Flooring Floor Wood stain Hardwood
Nice, Mike! Pretty and handy!
 

Attachments

#12 ·
Paul Sellers Kit

Router plane - Paul Sellers Hardware Kit

Paul Sellers has started selling a hardware kit for a router plane, and I quite fancied having one with a mechanical adjuster so I thought I'd give it a shot.
It's basically a modified hags tooth router with mechanical depth adjusters.

So, armed with the Paul Sellers Hardware Kit & a chunk of willow.
Wood Floor Flooring Wood stain Hardwood


Big check in the chunk, so I'll split that off first so I can see what i have to work with.
Lop it down to about a foot to work with.
Couple of small checks left, but they don't look like they will run in much further and I can mostly avoid them anyway.

Mark out an oversize piece for the main body and split it off.
Wood Rectangle Natural material Hardwood Lumber


Big knot there, so I'll cut that end off as well.
Wood Wood stain Hardwood Varnish Office ruler


And make it roughly square with a scrub plane.
Wood Machine Gas Machine tool Metal


Cut it to size.
Wood Floor Hardwood Wood stain Flooring


Wood Hardwood Wood stain Rectangle Gas


And square it off - It's a Paul Sellers kit so I think if you don't use a Stanley Number 4 at some point in the build some serious looking men in plaid come and take you away.
Smoothing plane Plane Scrub plane Jack plane Hand tool

Wood Hardwood Machine Cuisine Auto part


And cut a 1 1/4 inch hole for the throat, I'd never used this bit before and didn't check it well enough - the outside of the spur had been filed down from the look of it, so it wandered a little - No great worry, I can fix the hole up later.
Wood Hardwood Flooring Art Tool


Onto making the pieceon top where all the hardware goes.
Cut of a chunk and square off 2 reference faces.
Wood Hardwood Wood stain Font Plywood


Wood Hardwood Flooring Font Metal

Food Wood Cuisine Ingredient Dish

Mark the angle that the iron is going to be at - I'm going for 60 degrees on this one.

I was going to cut it to shape at this point but changed my mind as I think it will be simpler to add the holes and cut-outs for the kit with it squared off instead, so square the other 2 sides.

Which brings me on to the kit, it turned up in a neat little box that even the postal service hadn't dented.
It contains all the metal hardware you need to make the plane.
Brown Wood Gas Hardwood Flooring


Wood Gas Audio equipment Hardwood Metal


So, cut out a slot for the iron and fit it so it's just a little proud of the surface.

Wood Flooring Floor Hardwood Wood stain


Bottle Table Tool Wood Hand tool


Mark out where the adjuster goes and drill the hole - I'd have normally freehanded this, but the pillar drill is a new toy so I'm using it.
Wood Flooring Floor Wood stain Hardwood


Blue Wood Milling Machine tool Electrical wiring


And mark out and drill the holes for the retaining bar.
Wood Wood stain Hardwood Gas Plywood


Pneumatic tool Drill Wood Handheld power drill Saw


Now I can shape the piece to give a 60 degree angle for the iron.
Wood Wood stain Hardwood Natural material Metal


And it goes a bit like this - I'll shorten the back and blend it in after it's glued on.
Brown Wood Rectangle Hardwood Wood stain


Smooth off the side edges of the piece with some rasps and sandpaper.
Wood Hardwood Engineering Wood stain Lumber

Wood Wood stain Flooring Hardwood Tool


On to shaping the main body.
Angle and shape the front.
Food Wood Cuisine Dish Staple food


Hand tool Wood Tool Metalworking hand tool Hardwood


And glue on the top piece.
Wood Wood stain Flooring Floor Hardwood


Match up the back and round it over to blend it in a bit.
Food Wood Cuisine Dish Cooking


On to the handles.
Paul Sellers just modifies some normal cupboard handles for his - I decided to just make them from scratch, mostly because I wanted squared off handles.

Cut off a chunk and square it off (Using a Stanley number 4, of course)
Wood Wood stain Flooring Hardwood Rectangle


Wood Cuisine Ingredient Hardwood Dish


And then rasp and chisel down to the shape I'm after.
Wood Rectangle Flooring Floor Wood stain


Wood Flooring Floor Table Wood stain


Wood Vise Hardwood Cuisine Gas


And then just round off the edges and seperate into 2 handles.
Wood Wood stain Rectangle Hardwood Varnish


Wood Hardwood Composite material Flooring Plywood


I didn't have enough visibility on the hole and it needed fixing a bit anyway, so I re-shaped it a bit while evening it out.
Wood Tool Wood stain Hardwood Composite material


Which just left re-drilling the holes to final depth.
Table Wood Tin can Wood stain Hardwood


Adding a quick coat of danish oil.
Wood Wood stain Hardwood Varnish Plywood


And attaching the hardware, I had a couple of bits left over that would have been used for the handles.
Smoothing plane Plane Wood Wood stain Hardwood
 

Attachments

#13 ·
Paul Sellers Kit

Router plane - Paul Sellers Hardware Kit

Paul Sellers has started selling a hardware kit for a router plane, and I quite fancied having one with a mechanical adjuster so I thought I'd give it a shot.
It's basically a modified hags tooth router with mechanical depth adjusters.

So, armed with the Paul Sellers Hardware Kit & a chunk of willow.
Wood Floor Flooring Wood stain Hardwood


Big check in the chunk, so I'll split that off first so I can see what i have to work with.
Lop it down to about a foot to work with.
Couple of small checks left, but they don't look like they will run in much further and I can mostly avoid them anyway.

Mark out an oversize piece for the main body and split it off.
Wood Rectangle Natural material Hardwood Lumber


Big knot there, so I'll cut that end off as well.
Wood Wood stain Hardwood Varnish Office ruler


And make it roughly square with a scrub plane.
Wood Machine Gas Machine tool Metal


Cut it to size.
Wood Floor Hardwood Wood stain Flooring


Wood Hardwood Wood stain Rectangle Gas


And square it off - It's a Paul Sellers kit so I think if you don't use a Stanley Number 4 at some point in the build some serious looking men in plaid come and take you away.
Smoothing plane Plane Scrub plane Jack plane Hand tool

Wood Hardwood Machine Cuisine Auto part


And cut a 1 1/4 inch hole for the throat, I'd never used this bit before and didn't check it well enough - the outside of the spur had been filed down from the look of it, so it wandered a little - No great worry, I can fix the hole up later.
Wood Hardwood Flooring Art Tool


Onto making the pieceon top where all the hardware goes.
Cut of a chunk and square off 2 reference faces.
Wood Hardwood Wood stain Font Plywood


Wood Hardwood Flooring Font Metal

Food Wood Cuisine Ingredient Dish

Mark the angle that the iron is going to be at - I'm going for 60 degrees on this one.

I was going to cut it to shape at this point but changed my mind as I think it will be simpler to add the holes and cut-outs for the kit with it squared off instead, so square the other 2 sides.

Which brings me on to the kit, it turned up in a neat little box that even the postal service hadn't dented.
It contains all the metal hardware you need to make the plane.
Brown Wood Gas Hardwood Flooring


Wood Gas Audio equipment Hardwood Metal


So, cut out a slot for the iron and fit it so it's just a little proud of the surface.

Wood Flooring Floor Hardwood Wood stain


Bottle Table Tool Wood Hand tool


Mark out where the adjuster goes and drill the hole - I'd have normally freehanded this, but the pillar drill is a new toy so I'm using it.
Wood Flooring Floor Wood stain Hardwood


Blue Wood Milling Machine tool Electrical wiring


And mark out and drill the holes for the retaining bar.
Wood Wood stain Hardwood Gas Plywood


Pneumatic tool Drill Wood Handheld power drill Saw


Now I can shape the piece to give a 60 degree angle for the iron.
Wood Wood stain Hardwood Natural material Metal


And it goes a bit like this - I'll shorten the back and blend it in after it's glued on.
Brown Wood Rectangle Hardwood Wood stain


Smooth off the side edges of the piece with some rasps and sandpaper.
Wood Hardwood Engineering Wood stain Lumber

Wood Wood stain Flooring Hardwood Tool


On to shaping the main body.
Angle and shape the front.
Food Wood Cuisine Dish Staple food


Hand tool Wood Tool Metalworking hand tool Hardwood


And glue on the top piece.
Wood Wood stain Flooring Floor Hardwood


Match up the back and round it over to blend it in a bit.
Food Wood Cuisine Dish Cooking


On to the handles.
Paul Sellers just modifies some normal cupboard handles for his - I decided to just make them from scratch, mostly because I wanted squared off handles.

Cut off a chunk and square it off (Using a Stanley number 4, of course)
Wood Wood stain Flooring Hardwood Rectangle


Wood Cuisine Ingredient Hardwood Dish


And then rasp and chisel down to the shape I'm after.
Wood Rectangle Flooring Floor Wood stain


Wood Flooring Floor Table Wood stain


Wood Vise Hardwood Cuisine Gas


And then just round off the edges and seperate into 2 handles.
Wood Wood stain Rectangle Hardwood Varnish


Wood Hardwood Composite material Flooring Plywood


I didn't have enough visibility on the hole and it needed fixing a bit anyway, so I re-shaped it a bit while evening it out.
Wood Tool Wood stain Hardwood Composite material


Which just left re-drilling the holes to final depth.
Table Wood Tin can Wood stain Hardwood


Adding a quick coat of danish oil.
Wood Wood stain Hardwood Varnish Plywood


And attaching the hardware, I had a couple of bits left over that would have been used for the handles.
Smoothing plane Plane Wood Wood stain Hardwood
Terrific post Mike!
I've been tempted to make a router plane but always seem to find something else to do instead. Your post may have put me over the top to put a plane like this on the to-do list.
Loved "some serious looking men in plaid come and take you away."
Happy planeing!! (If that's actually a word…oops here comes some serious looking men…oh well you get the piciture!).
 

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