>Hi Guys, here is my latest project, they are A5 smoothers with cocobolo infill, the soles are 1/4 inch mild steel and the sides 3/16 inch brass, the irons are 01 steel made by Darryl Hutchinson. They have taken me an age to make and I now have arms like Popeye after all that lapping.
I live in wet and windy South Surrey B.C. if anyone would like to try one out.
No it's me who's stupid, they are A13's not A5's ,sorry about that.
See if I can answer some of the questions
I intend to sell 4 of the planes
They are all the same and bedded at 50 degrees
I made all the adjuster, the caps and the screws ( I was going to include a pic of some spare ones I made but my camera does not seem to want to play anymore)
I am not a tool maker,(I'm a machinist by trade) but have made a few others in the past
(14 1/2 inch panel , A31, mitre plane, 1 1/2 inch shoulder plane and a couple more A13's)
I am asking $1000 canadian
And these have taken such a long time to make , I am going to do a little woodworking for a while
>Keith, very nice and consistent work. I'm pretty curious about how different makers go about forming the side profile, and in your case chamfering the contour.
As a machinist, I guess you had a number of choices. Actually, I speculate sometimes that the 19th century approach may have included four-bar linkage mechanisms to control the path of the stock or the tool. But that's beside the point.
Your choices with the profile/contour might have been: 1)bandsaw (to a line or with a template), 2) CAD-CAM-CNC, 3) milling freehand to a line with a highly coordinated x and y axis reflexes and a fine multitasking brain, 4) stamp out with die and punch press (huge), or 5) what have I left out. Oh! Cold chisel, hack saw and files.
Then, as I say I wonder the same things about the chamfering.
Hope you, and perhaps others, might mention the details and choices.
>I'm with you Bob, that champer alone the upper sides always kills me. It looks sooooooooooo purdy. My guess is that today it's done by machine, but would like to know for sure how it was done in days of yore.
>Konrad Sauer told me this himself, as I was holding one of his A2 jointer plane in Almonte, (yes, this is my best gloat to date, as I'll probably never own one.)
>I find that working metal is easier than working wood because you cannot remove material nearly as fast in metal (by hand, that is). Also, metal is brighter, so the lines show up better. I think it is easier to see when a chamfer is off a little bit and correct it in metal than wood. I am not trying to negate the skill level shown here, just saying that I think it is not impossible to achieve if that is your goal.
>After seeing what some carvers can do, as well as the shapes that woodworkers can achieve by hand (take a look at Mike W's saw handles for instance), a simple polished chamfer on metal seems like no impossible feat, even if it does take skill.
Firstly I mill the soles,the dovetails and the mouth opening (undersize), then transfer the dovetails into the brass plate sides that have been pop riveted together, then mill the side dovetails.
I have a template of the sides that I photocopy and glue onto the sides ,aligning the dovetails, I use this as a guide to bandsaw the sides and drill the holes for the retaining rivets . I will now finish the contour(while still pop riveted) with various shaped files.
With the shaping finished I use Hermaphrodite(odd leg) calipers to scribe a line where the chamfers need to be, then using files again, file to the line.(But you will have to retouch these up after the sides have been lapped) The pop rivets are removed and the two inside side are now polished before assembly.
>Clearly an enormous amount of skill and hard work: freehand bandsawing to a line and then handfiling the chamfers. My hat's off to you. Thanks for sharing the details. Since you did multiples it made me wonder if you had access to CNC cutting via plasma, waterjet, and so forth. I believe I remember the Shephard boys said they jobbed the cutting out to a volume CNC operation. To me, it's easy to think of supporting one-off multiples of an infill like yours, more than a Henry Ford assembly line of jobbed out components. But my attitude stems from opinion and preference, many infill kit fans evidently thought of Shephard as a godsend. I wish you great luck recovering a little $$$ for your inspired and hard work.