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Let's Build an Infill Shoulder Plane! #4: Final Shaping

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Blog entry by Ripthorn posted 367 days ago 1690 reads 0 times favorited 12 comments Add to Favorites Watch
« Part 3: Rough Shaping Part 4 of Let's Build an Infill Shoulder Plane! series Part 5: The End »

Well, the finish line is well in sight now, boys and girls! This is the second-to-last installment of our series, so let’s get going!

Tools used:

Belt sander
dremel with aluminum oxide grinding stones (see tips in last episode)
spindle sander
needle files
triangle file
flat mill bastard file
sandpaper
granite plate
block plane

So first things first, I went to work to use the beefy belt sander again. I used it to shape all the convex curves. This made it much faster. A big strong belt sander sure helps. I bet a handheld belt sander would also work well, as those things have boatloads of torque. My belt sander is just my ridgid combo belt/spindle sander and the belt attachment doesn’t let you really bear down on it. Anyway, after another fire-free episode at work, we have something like so:

With this taken care of, I got the infills down to width. This was a more time consuming process than I had anticipated. I think that this will be another benefit of precision ground stock: you can use the planer to get the stock to just thicker than the width of the sole piece. Then when it comes time to fit, a hand plane can take just a couple shavings to final fit. I ended up trimming on the table saw and using a block plane to final fit. I put them in and used an awl to trace the shape and rough trimmed on the band saw to just over the line. We’ll use a belt sander and spindle sander later to get it all down to where it should be.

USEFUL TIP

I epoxied in the infills. Because the rear infill is going into a confined space, I cut some saw kerfs into the side and trimmed off the very tip of the infill so that any excess epoxy has a place to go.

After it dried, I used the sander to get everything looking nice. While drying, I worked on the lever cap. I just used sandpaper to get sanded up to 400 grit. It looks pretty good if I say so myself:

So here they are together (so happy together…)

So the final touch now is a chamfer along the sides. What I did was use my calipers set to half the width of the side steel pieces and locked the measurement in. I used this as a scribe, since the tips are hardened. You can sort of see it here:

I found that this was a little hard to see in practice, so I used a black sharpie along the lines and re-scribed. Here is a shot of that:

You could just as easily use bluing, but I don’t have any.

LESSON LEARNED

Don’t scribe the line too deep, otherwise it will be a bear to get sanded out, especially this late in the game.

So I went to work with primarily the flat file. This was actually surprisingly quick work. The hardest part is inside the curve. If I had a full size half round file, it would be gobs easier. As it was, I used a half round needle file. That made things not so fun. I followed up the file with sandpaper up to 400 grit.

After the chamfer, I just sanded the sides up to 400 grit. I then put it all together just to give it another use. After these shots, I put some Formby’s low gloss tung oil finish on it. The next installment will cover the lever cap screw and some final tuning.

Time Elapsed to this point: ~22 hrs

-- Brian T. - Exact science is not an exact science



12 comments so far

View ShaneA's profile

ShaneA

4966 posts in 1099 days


#1 posted 367 days ago

Wow…really looking good.

View jap's profile

jap

1218 posts in 554 days


#2 posted 367 days ago

great work

-- Joel

View RGtools's profile

RGtools

3257 posts in 1155 days


#3 posted 367 days ago

This is pretty darn impressive.

-- Make furniture that lasts as long as the tree - Ryan

View Mauricio's profile

Mauricio

6693 posts in 1652 days


#4 posted 367 days ago

Wow, I love it. At first I wasn’t sure about where you were going with the shape but now I really think it is turning out great! Looks amazing man!

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View Mosquito's profile

Mosquito

4094 posts in 793 days


#5 posted 367 days ago

Man that looks great. Excellent work.

-- Mos - Twin Cities, MN -- Stanley #45 Evangelist - www.youtube.com/MosquitoMods

View Don W's profile

Don W

13928 posts in 1068 days


#6 posted 367 days ago

Unless you’ve done this, you don’t realize how much work went into this. Very well done.

-- There is nothing like the sound of a well tuned hand plane. - http://timetestedtools.wordpress.com (timetestedtools at hotmail dot c0m)

View Roger's profile

Roger

13062 posts in 1304 days


#7 posted 367 days ago

Gr8 build

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View Ripthorn's profile

Ripthorn

665 posts in 1485 days


#8 posted 367 days ago

Don, you’re not kidding. Though I do figure that if I use better stock, that alone would have saved me 5-7 hours on this build. I have additional process refinements in mind that will hopefully get me to the 15 hour mark or so from start to completion. Of course, that will be a different blog series once this gets all finished up. And let me say that the finish on the walnut makes the contrast really pop! Hopefully the next blog entry will be in 2-3 days when it will be all done. Then I’ll just have to figure out how to adjust the darn thing :)

-- Brian T. - Exact science is not an exact science

View waho6o9's profile (online now)

waho6o9

4448 posts in 1077 days


#9 posted 367 days ago

The oval and the curves have an appealing look to the eye.

Me likey the proportions of your fine work.

A suggestion if I may? Infill knob for the top of the screw adjuster?
http://www.bridgecitytools.com/default/other-products/clearance.html?limit=all

View Don W's profile

Don W

13928 posts in 1068 days


#10 posted 367 days ago

My last build was with precision ground. You are correct, its a much better experience.

I bought way to many of the knobs waho6o9 posted above. If you want one its yours, just PM me your shipping address. (I think they are 1/4×28 threads)

-- There is nothing like the sound of a well tuned hand plane. - http://timetestedtools.wordpress.com (timetestedtools at hotmail dot c0m)

View Ripthorn's profile

Ripthorn

665 posts in 1485 days


#11 posted 367 days ago

I was thinking of making an infill knob sort of like what wahoo posted, but since you offered, Don, I’m totally PM’ing you, as that will save me a bunch of work!

I am actually looking forward to using precision ground stuff. Should be fun.

-- Brian T. - Exact science is not an exact science

View waho6o9's profile (online now)

waho6o9

4448 posts in 1077 days


#12 posted 367 days ago

+1 for DonW

2 cool

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