Let's build a small infill smoother!

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Blog series by Ripthorn updated 03-08-2015 02:43 PM 5 parts 14282 reads 30 comments total

Part 1: Intro and Rough Metal Working

02-18-2015 03:23 AM by Ripthorn | 11 comments »

As some of you may be aware, I did a series on building an infill shoulder plane a couple years ago. I followed that up with a series building a twin pair of infill shoulders. Well, I have had the materials (left over from the infill shoulder prototype) laying around for a prototype of the small infill smoother like Ron Brese makes. Ron has been very generous with his information over the years, but at $2100 for one of these little guys, I want to try my hand at this. This will be a pro...

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Part 2: More Metalworking

02-20-2015 03:35 PM by Ripthorn | 4 comments »

Alright, so last time we left off with some holes drilled and infills roughly cut. Before I could transfer the holes from the sides to the sole pieces, I needed to make sure that the mouth spacing would be right for my (anticipated) 3/16” thick iron. Now, you will remember that the sole pieces had the angles rough cut on a bandsaw. This actually did a pretty good job, but there were still marks that needed to be removed. I decided that while removing the marks, I would also clamp ...

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Part 3: Filling it in

02-21-2015 04:15 AM by Ripthorn | 6 comments »

Alright, here we are again. I discovered that peening threaded rod is not a wise idea. I had some longer flat head, slotted screws that were about 3” long, so I cut them down to about 1/2”, used some epoxy (a few got red loctite, just to see what difference if any there exists in this application) and was able to get most of the screws in. After that, I decided to shape the rounded profile of the front and rear. I have a 40 grit blue sanding belt (aluminum zirconia) that I h...

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Part 4: Shaping up

02-21-2015 10:48 PM by Ripthorn | 4 comments »

This has been coming along surprisingly quick, but I am coming up on a little bit of a wait after this installment. So with the epoxy set on the infills, I used the band saw to rough cut the ends of the infills. Then I used the belt sander to take them down to shape. After that, it was time to shape the top curvature of the infill. This was done by first marking the center line: After 10 or 15 minutes at the belt sander (still using the 40 grit blue belt), I got this: The ...

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Part 5: The Finish Line

03-08-2015 02:43 PM by Ripthorn | 5 comments »

Alright, I haven’t posted in a little while owing to needing to make a blade. Well, the stock came and I finally made one. It is 5/32” O1 that is just a tiny bit narrower than the plane opening to allow for side to side adjustments. I put in brass wood screws into the infills. I used Philip’s head screws and used an automatic center punch to punch as much material as possible into the drive cavity before peening. It turned out really well on 5 of the 6 screws. On the...

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