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 have never used, but these are made primarily for sanding steel and other hard metals. I put it on, and all I can say is “Wow!” These are totally worth every penny. I just worked the profiles by hand, ultimately ending up with this:
That meant that next up was putting in the infills. I decided to use epoxy and then I would do screws into the infills after the epoxy was set. This was to ensure that the bedding was perfectly flat and lined up. So I cleaned the metal with denatured alcohol and scored the infill to give the epoxy something to bite into. I just used a marking knife, like so:
I mixed up some 5 minute epoxy, put in the bedding infill, and positioned it so that it mated perfectly with bedding part of the sole. It took a couple tries, but wasn’t hard to do. Then I did the front infill. There was a small gap that I close up with a clamp:
I had a little bit of shop time left, so cut a 2” piece of 3/8”x1 1/2” steel that will be my lever cap. It’s this short because it’s a small plane. Here is what we start with:
And after about 10 minutes with the sanding belt, I got to this point before coming in:
I will further refine the shape, drill and tap for the screw, and then drill for the pivot screws next. That also means I will need a blade. I put in my 3/16” scraps ground like a blade and the mouth is totally closed. I anticipate using 5/32” O1 for the blade, so that should be just fine. I can always open it more, but I can’t close it in.
- The blue aluminum zirconia belts are the most awesome thing for shaping metal
- Gaps in infills is bad, but tiny ones disappear
- Don’t try to peen something that has just been epoxied in, it won’t end well
Total time to this point: ~6 hrs
We are getting close. If I had the steel for the blade on hand, I just might be able to take some test cuts tomorrow. We’ll see.
-- Brian T. - Exact science is not an exact science