Hand Plane Tote Repair For A Missing Horn

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Blog entry by LukieB posted 722 days ago 1810 reads 1 time favorited 10 comments Add to Favorites Watch

I have quite a few vintage Stanley plane totes that look like this. Seems to be a very common form of damage, guess maybe the first thing to hit the ground when they fall.

First thing I did was clean up and straighten out the damaged area with a sharp chisel, and then on my granite slab with sandpaper on it.

This one was damaged far enough down that the counter-bore was gonna be an issue. The hole had to be drilled before being glued on there. I just eyeballed the angle at first.

I left plenty of meat on the new piece so the drill angle could be adjusted by taking some off the side that would be glued to the tote. I then used a 7/16” dowel to line up the glue surfaces just right.

The dowel also helped me line up the holes for gluing and clamping, I just wrapped it in tape so the epoxy wouldn’t stick it in there for good.

I probably could have used regular wood glue since the glue surfaces were flat and mostly long grain. But the last one I did was kind of a goofy grain, and I had bought epoxy for that, so I used it.

Here it is after the bandsaw,

And the edge-sander/spindle sander,

And the japanese rasp,

And a whole lotta sanding,

And, some finish. Trans-tint dye with denatured alcohol to tone the patch, followed by a clear coat of lacquer .

It was dark by the time I took the last pic, and the flash makes it look way darker than it actually is. With some better light it looks pretty good if I don’t say so myself.

And, of course a couple shots of the beautiful 5-1/2 it belongs on.


-- Lucas, "Someday woodworks will be my real job, until then, there's this"

10 comments so far

View Don W's profile

Don W

14910 posts in 1204 days

#1 posted 721 days ago

nice save on a very nice 5 1/2.

-- Master hand plane hoarder. -

View racerglen's profile


2298 posts in 1417 days

#2 posted 721 days ago

Beauty !
Very nice work Lucas.

-- Glen, Vernon B.C. Canada

View Smitty_Cabinetshop's profile


9830 posts in 1255 days

#3 posted 721 days ago

Very nice work, indeed!

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive

View terryR's profile


3061 posts in 945 days

#4 posted 721 days ago

Great job, Lucas! And thanks for the photos of the cut and pasting…gives me more confidence to try it, too.

-- tr ...see one, do one, teach one...

View Mosquito's profile


4650 posts in 929 days

#5 posted 721 days ago

Very nice job! You almost can’t even tell it was repaired.

-- Mos - Twin Cities, MN -- Stanley #45 Evangelist -

View LukieB's profile


921 posts in 967 days

#6 posted 721 days ago

Thanks guys, sure appreciate the nice comments!

-- Lucas, "Someday woodworks will be my real job, until then, there's this"

View bern92's profile


71 posts in 1992 days

#7 posted 721 days ago

WOW! nice job, well done

View AnthonyReed's profile


4579 posts in 1077 days

#8 posted 721 days ago


-- ~Tony

View TechRedneck's profile


738 posts in 1494 days

#9 posted 721 days ago

Nice write up.

It reminds me that I have to pick up some rasps. Smart idea doing from bandsaw to spindle then rasp.

-- Mike.... West Virginia. "Man is a tool using animal. Without tools he is nothing, with tools he is all.". T Carlyle

View leeman's profile


13 posts in 241 days

#10 posted 76 days ago

I have seen almost replica of this hand plane at a local furniture and door shop along Bay Area in San Francisco, you can check this for the store.

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