There’s lots of planes in my workshop that need a refurbished tote to make them usable. They are all projects for a later date, I keep telling myself. This is a typical tote, found on a transitional #27 on one of my hunting trips:
Here’s what I do: To fix the broken horn, I first bandsaw off the stub, leaving as flat a surface as possible.
Then, after confirming a nice flat surface, I select a little block of wood of similar grain, and glue it on. I keep exotic little cutoffs around, just for this reason. Simple walnut will suffice, and it rasps easily. I’ve tried bubinga, padauk, bloodwood, nahhh, don’t spend money on exotic wood unless your shooting for a world-class restoration.
Use any kind of fixturing necessary to get a good clamping pressure.
Then, trace an outline of the new “shark-fin” or sketch it freehand, and bandsaw it out::
Using rasps and files, rough in the new horn to the contours of the tote:
Photos are of several different totes in various stages, in case you wondered.
A bit of sanding, for ‘fairing in the contours to the original tote, and some finishing:
Hey.. don’t use ancient shellac like I did… it won’t lie flat, and took too long to dry.
Oh, well a bit of fine sanding, and fresh shellac over the Minwax dark red mahogany stain, kinda makes the wood look like rosewood.
Big thanks to DonW, whose writings taught me that broken totes are not only repairable, but can be beautiful utilitarian works of art!!
ps Apologies to those who commented before this thread got re-posted!!
-- 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!!