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1st Try at Infill Finally Done!!!

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1st Try at Infill Finally Done!!!

#1

1st Try at Infill Finally Done!!!

ray k

>After much work, I've finally managed to get this plane off and flying. There are some things about this plane I'm not happy with, but I think overall I'm pretty happy with the way it came out--especially since I had no experience making any planes (even wooden ones until I decided to make this one).

Thanks to everyone for their suggestions on what wood for the infill, whether my version of an adjustable throat would work, and the kind words of encouragement.

So the vitals: Bought the rough casting, blade, cap iron, adjuster from St. James Bay Tool Co. The wooden handle & knob were made of laminated cocobolo and macassar ebony and epoxied onto the casting. Finished all the wood parts with a couple wipe on coats of olympic antique oil and buffed with a thin layer of renaissance wax. Shopmade adjustable throat insert is made of brass.


Hand sanding & polishing the bronze got to be too tiring. I took a break, looked at my LN planes and realized that I'm intending on making this baby work. And since my LN planes have ding marks on them, why kill myself trying to make this plane pretty.



I have to confess that for the first hour or so after this plane was completed, I kept handling the knob and handle. Call it pride or a lack of something better to do, but in either case, the feel of that silky finished wooden handle really makes me want to show it off to anyone who will listen.

I still can't believe I actually made this. I really thought that even considering making something like this (especially with all the metalworking involved) was crazy.


Here's one of the first few shavings this plane took off a piece of birdsye maple. My caliper measured 0.001". But I did notice that the shavings would range anywhere from 0.0005 to 0.007. I think I might have to try and tune this a little bit more later down the line. I think I O.D.'ed on making this plane for the time being. It's time to make some real furniture. Oh yeah, I still need to figure out some way to personalize this. Steel stamping set with letters and numbers?


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Re: 1st Try at Infill Finally Done!!!

#2

Great work!

Mark Harrison -- in Sydney, Australia

>I'm exceedingly jealous.

Re: 1st Try at Infill Finally Done!!!

#3

Re: 1st Try at Infill Finally Done!!!

Bruce, a MN galoot

>Great job and inspiration for me. I have one of those infill castings, 90% finished, just need to flatten the bed, attach the tote and knob and put it to work.

Very nice work!

Bruce

Re: 1st Try at Infill Finally Done!!!

#4

Where's the hang hole?

Jim Reed @Tallahassee

>Great work!!!

Re: 1st Try at Infill Finally Done!!!

#5

Gee, I feel like a proud godfather

Don Thompson - Cutler Ridge, Florida

>I sent you to Bob at St. James Bay on 1/10/05, and 39 days later.... ta-dah!

Looks great!

Re: 1st Try at Infill Finally Done!!!

#6

Might I suggest...

Bob Hackett

>You simply sign it and maybe date it.Sign it with an engraver and then go back over it with a small burr in a dremel or die grinder after practicing on scrap brass.

I would also put an account of the whole process somewhere where it can be connected with the plane after you`re gone.

Picture your GG-grandchildren pulling up holographic images while they hand the plane to thier WWing friends and telling how they come from a long line of accomplished craftsmen.The plane and story will be proof of that.

Very nice work,and in record time too.

Mainely,Bob

Re: 1st Try at Infill Finally Done!!!

#7

Re: 1st Try at Infill Finally Done!!!

John Meikrantz

>I've built one of the Shepherd kits (just the chariot plane), and I've been interested in the St. James Bay stuff too. How difficult was it to work with the rough casting? What kind of tools are required for that? Has anyone built both a dovetail style and a casting style plane that can comment?

Oh, and great job! The plane looks fabulous!

John

Re: 1st Try at Infill Finally Done!!!

#8

Re: 1st Try at Infill Finally Done!!!

Ernie Miller Topeka

>Looks shiney enought to me. Looks good I like it.

Re: 1st Try at Infill Finally Done!!!

#10

Great work. Congrats- thanks for sharing

Curtis TX

>

Re: 1st Try at Infill Finally Done!!!

#11

Re: 1st Try at Infill Finally Done!!!

Dan Clermont in Burnaby

>Atta go Ray!!!

Sure is a nice plane and one you will always cherish in your collection.

So how rough are the rough castings from St James bay and how do you go a bout cleaning them up?

Thanks,

Dan Clermont

Re: 1st Try at Infill Finally Done!!!

#12

Re: 1st Try at Infill Finally Done!!!

steve knight

>very nicly done.

Re: 1st Try at Infill Finally Done!!!

#13

Nice going Ray!

Paul in NJ

>May it work as well as it looks.

Paul Dzioba

Re: 1st Try at Infill Finally Done!!!

#14

WOW!

Scott Burr in Ben Lomond CA

>That's one pretty nice looking plane! As a first attempt, I'd be proud and babbling about it too! Excellent job on the wood too, I like the looks of it.

How�s about a pic of the bottom with the adjustable mouth?

Re: 1st Try at Infill Finally Done!!!

#15

Very nicely done...add it to my roundtoit list

Robert Tarr

>

Re: 1st Try at Infill Finally Done!!!

#16

Re: Gee, I feel like a proud godfather

ray k

>Thanks a lot for the tip. Even though you led me down a path of non-woodworking, it was nevertheless really fun.

Re: 1st Try at Infill Finally Done!!!

#17

Re: 1st Try at Infill Finally Done!!! *LINK*

ray k

>Unfortunately, I've never tried making a plane from Shepherd, so I can't really compare the two. As for machining the casting--it's not as hard as I thought. I was really, really worried that I had bitten off more than I could chew. But I must say that this whole project stemmed from my enrolling in a 5 week machine shop class. I decided to make something useful (an infill!) instead of milling and drilling some scrap piece of metal. Overall, it was definitely a educational and rewarding project.

If you're considering machining one of these babies, I'd recommend getting the parallel smoother rough casting instead of the round-sided version I chose. The round-sided version involved a little bit more work and consideration. If you get the chance to mill a rough casting, you'll at least develop the skill/confidence to even try making an infill from some steel channel. So I'm now thinking about making another infill or panel plane from scratch (no casting or kits). But that probably won't be for awhile. I need to work on some furniture and I'll probably try to shoot for the summer 5 week class section so I can access to the school's milling machine.

It's definitely doable. But you'll need access to a milling machine with all the necessary end mills, drill bits, etc.

I posted some notes and more pix of my progress during this whole process. If you're interested click on the link below and scroll down.


http://www.thenewchinkyworkshop.com/neanderthalparadise.htm

Re: 1st Try at Infill Finally Done!!!

#18

Re: 1st Try at Infill Finally Done!!!

ray k

>Thanks for the kind words. As for the rough castings, here's how they looked straight out from the box.

The end mill on a milling machine will make the casting amazingly shiny just by the milling process alone. But I did shape the plane with metal files and sandpaper. It's just like shaping wood, except it takes longer.

When I first filed and milled the rough bronze casting, the shininess of it really amazed me. The amazement was akin to the reaction I first had when jointed rough cut lumber for the first time--it's like you unlocked an amazing treasure from a battered up treasure box.




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Re: 1st Try at Infill Finally Done!!!

#19

Re: WOW!

ray k

>Thanks for your comments. I put some pics of the adjustable throat ahile back, so sorry if these are repeats, but here they are:

the sole wasn't lapped flat yet in this photo.


the adjustable throat design is nowhere near as elegant as the ones I've seen here (e.g. SMT Loopy). But the adjustable throat was a last minute fix for when I accidentally milled the throat opening too wide. So I'm content with it. It's not that convenient to have to loosen the machine screw from the sole to adjust the throat. But I'm planning on leaving the throat insert right where it is.


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