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Building an infill smoother #2: Sides and infill build

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Blog entry by Wally331 posted 08-22-2013 02:53 AM 1390 reads 0 times favorited 9 comments Add to Favorites Watch
« Part 1: Inspiration and cutting out the sides Part 2 of Building an infill smoother series no next part

Sorry it’s been so long between entries, two-a-day football practices sort of got in the way ;) I guess I’ll continue where I left off…

While I was waiting for my steel to arrive from McMaster- Carr I moved my attention to the infill. I had to slightly re-size and refine my original drawing to the final bed angle(50 degrees) and plan out exactly where I wanted the bolts and how the infill would fit in.

I used my new drawing to make some paper templates which I just glued right onto the padauk. From there it was a simple job for my bandsaw. After I had it glued up- I moved to rasps, files and sandpaper to finish up the tote and knob.

My newly built router lift came in very handy to mill the slot needed for a chipbreaker screw. Here is the knob and tote all finished up ready for the sides and sole-

By the time I was finished with the infill, my steel had come. I laid out where I wanted the bolts and drilled 10 holes on each side. The drill bit was somewhere between 3/16 and 1/4 so that I could tap quarter inch by 20 threads.

It took quite awhile but I got them all tapped. I brought out my trusty jb weld, mixed it up and just spread it around like a normal glue up. A couple dabs on the threads and along the sides ensure a very strong bond. Next I simply screwed the bolts in, and cut them off with a hacksaw.

After a poor job of peening the heads over, I filed them smooth. There is a noticeable difference between my first few rivets and my last, I got considerably better along the way. A little work on the belt sander after and everything was looking pretty good. I test fitted the infill and was pleased, I think there is still hope it might turn out into something half decent looking ;) That’s all for today, I’m thinking that the next blog will show the finished piece.



9 comments so far

View Don W's profile

Don W

15521 posts in 1313 days


#1 posted 08-22-2013 11:25 AM

great stuff Wally!

-- Master hand plane hoarder. - http://timetestedtools.com

View chrisstef's profile

chrisstef

11455 posts in 1752 days


#2 posted 08-22-2013 12:10 PM

I cant wait to see that all shined up Wally. Gonna make one hell of a smoother.

-- "there aren’t many hand tools as awe-inspiring as the #8 jointer. I mean, it just reeks of cast iron heft and hubris" - Smitty

View BTimmons's profile

BTimmons

2177 posts in 1231 days


#3 posted 08-22-2013 03:25 PM

The forward “swoop” look of this thing is gonna look like a really slick sports car by the time you’re done. Can’t wait.

-- Brian Timmons - http://www.BigTWoodworks.com

View Rev. Jim Paulson's profile

Rev. Jim Paulson

118 posts in 2022 days


#4 posted 09-10-2013 11:44 AM

This will be an awesome tool to use. Congrats on your wonderful tool making ability. Can you tell me how you
cut out the profiles on the sides? I’ve restored old planes and made a couple Krenov style planes, but haven’t tried to make an infill yet. Thanks again for sharing this project.

-- www.chairsbypaulson.com

View Don W's profile

Don W

15521 posts in 1313 days


#5 posted 09-10-2013 01:29 PM

@Rev Jim, in this Blog I have a list of infill references. You’ll find lots of way to work the steel from a hack saws to milling machines to go along with Wally’s answer.

-- Master hand plane hoarder. - http://timetestedtools.com

View Rev. Jim Paulson's profile

Rev. Jim Paulson

118 posts in 2022 days


#6 posted 09-10-2013 03:38 PM

Thanks Don. I would love to build an infill smoother and it is neat to know some folks on this site who have already made such beautiful planes such as Wally and yourself. I don’t own a metal lathe or a mill, but I’m hopeful that you can make one without them. I’ll be sure to check out those references for a start.

-- www.chairsbypaulson.com

View Don W's profile

Don W

15521 posts in 1313 days


#7 posted 09-10-2013 03:39 PM

I don’t own a metal lathe or a mill either.

-- Master hand plane hoarder. - http://timetestedtools.com

View Wally331's profile

Wally331

294 posts in 771 days


#8 posted 09-12-2013 03:19 PM

Well, I’m not an expert, but the best way to go is a metal cutting bandsaw in my opinion. I had to use a hacksaw for all the sides though, it took a lot longer, but it got the job done. A little filing after and it turned out fine. I also don’t own any metal working tools other then files, taps, and dies. You can make quite a lot of things with simple tools. Good luck.

View Don W's profile

Don W

15521 posts in 1313 days


#9 posted 09-12-2013 03:24 PM

I do have a metal cutting bandsaw.

-- Master hand plane hoarder. - http://timetestedtools.com

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