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Making the dw infills #4: Let do some tapping and peening.

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Blog entry by Don W posted 04-07-2013 12:56 AM 1836 reads 2 times favorited 20 comments Add to Favorites Watch
« Part 3: Part 3 the infill saga Part 4 of Making the dw infills series no next part

So another way to attach the sides is tapping and peening. I thought I’d give it a try on a small smoother. I decided on aluminum sides and hot rolled steel for the sole. The aluminum is 1/8” x 2” and hot the rolled steel is about 3/8” x 1 7/8”. I wanted to use a 1 5/8” block plane iron.

Infill is cherry.

Lever cap is brass.

This time I cut the sole in 2 pieces. I found this technique a lot easier. The I drilled the sides. And tapered them with a reamer.

Next I used the counter sink to give the holes a countersink. I figured between the taper and the countersink, they should tighten up nice.

The holes were the tapped 1/4×20

And the bolts tighten in. I really don’t think it would be necessary to use epoxy, but for the price of a tube of JB Weld, everything got welded.

Here I’m checking the depth to make sure I’m deep enough for the bolts.

bolt heads where cut off.

Then the bolts pened over.

I have about 6 hours in it at this point.

And a quick test run

Day 2

About another 4-5 hours.

I didn’t have a piece of metal for the cap iron (I may eventually just get a thicker iron) so I wound up using an old badly pitted #120 iron. It will be replaced.
The rest of the time was spent shaping the lever cap, making the chip breaker and sanding and finishing the plane.

Thanks for looking.

dw

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



20 comments so far

View RussellAP's profile

RussellAP

2963 posts in 1005 days


#1 posted 04-07-2013 01:05 AM

Great work Don. You could carve some wooden sides to make it more comfy, looks a little sharp, a good snag could result in getting blood all over your work. That’s a sin.

-- A positive attitude will take you much further than positive thinking ever will.

View Don W's profile

Don W

15397 posts in 1286 days


#2 posted 04-07-2013 01:07 AM

its not finished Russell. Hopefully tomorrow.

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

View poopiekat's profile

poopiekat

3709 posts in 2453 days


#3 posted 04-07-2013 01:15 AM

Really impressive, Don!
I’m going to make a 3/4” dado plane, but I’m not sure whether it will be in aluminum or wood, and I haven’t found a good idea yet that I can use for the nickers. I’m sort of leaning toward those replacement wheels for copper tubing cutters to scribe and cut ahead of either a chisel or Stanley #45 3/4” cutter. Keep up the good work, sir!

-- Einstein: "The intuitive mind is a sacred gift, and the rational mind is a faithful servant. We have created a society that honors the servant and has forgotten the gift." I'm Poopiekat!!

View ShaneA's profile

ShaneA

5411 posts in 1317 days


#4 posted 04-07-2013 01:32 AM

Is it my imagination, or are you cranking these things out in record time? You elves must be tired by now, I am.

View RussellAP's profile

RussellAP

2963 posts in 1005 days


#5 posted 04-07-2013 01:39 AM

Shane, he’s in serious danger of becoming a metal worker.

-- A positive attitude will take you much further than positive thinking ever will.

View Mauricio's profile

Mauricio

6867 posts in 1870 days


#6 posted 04-07-2013 04:10 AM

Wow Don, you made this one look even easier than making a wooden Krenov plane!

Poopie, I’m looking forward to seeing that dado plane!

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

View lysdexic's profile

lysdexic

4887 posts in 1341 days


#7 posted 04-07-2013 12:58 PM

How hard is it to keep everything square? It would be cool to make a dedicated shooting plane with your skill set.

-- It isn't the mountains ahead to climb that wear you out; it's the pebble in your shoe. - Muhammad Ali

View Jamie Speirs's profile

Jamie Speirs

4154 posts in 1575 days


#8 posted 04-08-2013 05:55 AM

Don thats a lot of work
However the results are well worth it
Jamie

-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View Brit's profile

Brit

5279 posts in 1561 days


#9 posted 04-08-2013 08:10 PM

I think this one is my favourite Don. I’ve always been partial to little infill smoothers. That’s a nice piece of cherry too. Great work as usual.

-- Andy -- Old Chinese proverb say: If you think something can't be done, don't interrupt man who is doing it.

View JayT's profile

JayT

2524 posts in 930 days


#10 posted 04-08-2013 08:54 PM

OK, infills are growing on me. Nice work, Don.

One question about sizing of the metal parts. With a 3/8 base plate and 1/4 in bolts, that doesn’t leave much metal underneath the spots that were tapped. Could this become a problem down the road if the sole needs re-flattened?

-- "The American Republic will endure until the day Congress discovers that it can bribe the public with the public's money." Alexis de Tocqueville, 1835

View Don W's profile

Don W

15397 posts in 1286 days


#11 posted 04-08-2013 11:20 PM

JayT. For anything much larger I’d probably go to 1/2”, but if you raised the threads up just a hair, I don’t think it would be an issue. That’s a lot of flattening by hand. If you think about it, a Stanley sole is only about 1/8” thick.

Thanks Andy.

Mauricio, I wouldn’t say easier than a krenov, but not difficult.

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

View AnthonyReed's profile

AnthonyReed

4992 posts in 1159 days


#12 posted 04-09-2013 03:05 PM

Don i know you are a wizard of some type but geez you are pumping these out in such numbers and increasing quality that is boggles the mind.

PK- Would the replacement cutting wheels for the Veritas marking gauges work as knickers?

-- ~Tony

View poopiekat's profile

poopiekat

3709 posts in 2453 days


#13 posted 04-09-2013 06:15 PM

Anthony: Hmm, yes I think they would come close…wonder if they’d really shear the grain, or just make an indent? I’ve got so many failed experiments, I’d hate to kill my $30 Veritas gauge just for the wheel; I’d thought of the plumber tubecutters only because they’re cheep at our local junk store…and I’d be machining into the aluminum slabs to fit whatever cutters I end up using… they’d better WORK or back it goes to my metals barrel…I will never be as prolific as our own DonW!

-- Einstein: "The intuitive mind is a sacred gift, and the rational mind is a faithful servant. We have created a society that honors the servant and has forgotten the gift." I'm Poopiekat!!

View AnthonyReed's profile

AnthonyReed

4992 posts in 1159 days


#14 posted 04-09-2013 06:20 PM

PK - Replacement cutters are $4.95 @ Lee Valley (#C or #D), no need to kill a gauge.

-- ~Tony

View mafe's profile

mafe

9606 posts in 1808 days


#15 posted 04-10-2013 01:46 PM

Really nice Don.
You have really become a plane creator.
I love your always relaxed approach – I can do that!
Lovely little plane.
Best thoughts,
Mads

-- Mad F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

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