Router Plane #3: Paul Sellers Kit

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Blog entry by MikeB_UK posted 06-16-2022 01:29 PM 563 reads 0 times favorited 11 comments Add to Favorites Watch
« Part 2: Spalted Birch Router Plane Part 3 of Router Plane series no next part

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.

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.

Big knot there, so I’ll cut that end off as well.

And make it roughly square with a scrub plane.

Cut it to size.

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.

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.

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

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.

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

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.

And mark out and drill the holes for the retaining bar.

Now I can shape the piece to give a 60 degree angle for the iron.

And it goes a bit like this – I’ll shorten the back and blend it in after it’s glued on.

Smooth off the side edges of the piece with some rasps and sandpaper.

On to shaping the main body.
Angle and shape the front.

And glue on the top piece.

Match up the back and round it over to blend it in a bit.

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)

And then rasp and chisel down to the shape I’m after.

And then just round off the edges and seperate into 2 handles.

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.

Which just left re-drilling the holes to final depth.

Adding a quick coat of danish oil.

And attaching the hardware, I had a couple of bits left over that would have been used for the handles.

-- Be yourself; everyone else is already taken.

11 comments so far

View sawdustjeff's profile


32 posts in 3033 days

#1 posted 06-16-2022 01:51 PM

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!).

View Oldtool's profile


3538 posts in 3682 days

#2 posted 06-16-2022 02:13 PM

Wow, nice write-up, great work. I like how you used hand tools to make a hand tool, and the finished tools looks fantastic. Enjoy using this new tool.

-- "I am a firm believer in the people. If given the truth, they can be depended upon to meet any national crisis. The point is to bring them the real facts." - Abraham Lincoln

View therealSteveN's profile


10186 posts in 2066 days

#3 posted 06-16-2022 03:41 PM

Great pic blog Mike. How is it for a user?

-- Think safe, be safe

View Eric's profile (online now)


5738 posts in 1365 days

#4 posted 06-16-2022 03:49 PM

Nice blog build. May have to tackle one these dome day.

-- Eric, building the dream. the "Loft"

View MikeB_UK's profile


1074 posts in 2526 days

#5 posted 06-16-2022 04:36 PM

Cheers sawdustjeff – I think I prefer making tools to most other stuff.

Thanks Oldtook, I need all the pics so I can look through it before the next one and try and make different mistakes next time.

Thanks SteveN, performs as I’d expect a higish angle router to perform – so more of a scraper then a plane. But I knew that going in when I picked the angle.
I’m liking the adjustment on it though, quick and easy to advance the iron.

Thanks Eric, pretty sure yours will end up nicer looking than mine.

-- Be yourself; everyone else is already taken.

View Dave Polaschek's profile

Dave Polaschek

10487 posts in 2074 days

#6 posted 06-16-2022 05:23 PM

Very thorough blog, Mike! Should enable a completely new set of mistakes next time!

-- Dave - Santa Fe

View MikeB_UK's profile


1074 posts in 2526 days

#7 posted 06-16-2022 05:58 PM

Cheers Dave – I’m reshaping the wing on that center bit for starters.

-- Be yourself; everyone else is already taken.

View controlfreak's profile


3869 posts in 1093 days

#8 posted 06-18-2022 04:09 PM

very nice! I like the log to start. Now every log looks like a router plane to me.

View MikeB_UK's profile


1074 posts in 2526 days

#9 posted 06-19-2022 06:09 PM

Thanks cf, I mostly start with a log because I’m a cheapskate and you can find them just lying around for free ;)

-- Be yourself; everyone else is already taken.

View Brit's profile


8519 posts in 4334 days

#10 posted 06-25-2022 12:29 PM

I remember watching Paul making one of those Mike and thinking it would make a nice project. Looks like you had a lot fun making it.

-- Andy - Old Chinese proverb says: "If you think something can't be done, don't interrupt man who is doing it."

View MikeB_UK's profile


1074 posts in 2526 days

#11 posted 06-25-2022 07:30 PM

Yeah, was a nice simple build Andy, I quite like willow, though it’s like beech – a bit awkward to see where the grain is going.

-- Be yourself; everyone else is already taken.

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