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Making an Infill Plane for Those of us Who Don't Like Working with Metal

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Project by Adam posted 1487 days ago 6261 views 61 times favorited 27 comments Add to Favorites Watch

I wanted a Infill but could not afford one and metal is really not my specialty. The answer was to take a $2.50 knock off Stanley # 4 and grind out the guts and stuff it with Mahogany. I bought a cheep tapp and die set and a small amount of 1/2” thick brass for $5 and made the lever cap with a stationary belt sander. The Brass is fairly soft and was easy to shape with only sand paper and a 1/2 round file. I tapped a 1/2” hole thought he top center for the cap screw, which is a stainless steel bolt with the top ground round. I tapped two holes into the sides of the cap and tapped it with 1/8” tapp and took 1/4” brass rod chucked it in the drill press and filed one end down so that it could be threaded. I used a hacksaw to cut a slot in the lever cap screws for easy removal.

I shaped the infill and clamped it in plane and then drilled and tapped it through the sides and attached it with 1/4” brass screws. I tapered the tops of the holes to allow the heads of the Screws to seat right in but I left them proud so that I could sand/file them flush with the sides and remove the screw head. They were pretty tight but I epoxy them in anyway so they would not come loose.

The blade is O1 tool steel I got from a friend that works at a machine shop. it is 3/16” thick and ground at 30 degrees and bedded at 55 degrees for tough grain and overall smoothing.

The hardest part was the bed for the blade and getting it perfect along with the holes in the sides for the Lever cap, which you can see I screw up by the elongated holes. Oh well next time it will be better.

It is very heavy compared to what I started with, but the heft helps with the momentum of the plane and it cut very nicely. I chose not to use an adjustor as it is intended to take very light shavings and once it is set up it most likely not be changed.

Hope you like and as always all questions and comments are welcome.

Thanks for looking.

-- Adam, St. Catharines, Ontario, Canada





27 comments so far

View Woodwrecker's profile

Woodwrecker

3559 posts in 2171 days


#1 posted 1487 days ago

Boy O Boy, talk about making a silk purse out of a sow’s ear!
Kid, you could go in to business doing that!
That thing is a beauty and I bet you get a ton of use out of it.
Nice Job !!!

-- Having fun...Eric

View CampD's profile

CampD

1188 posts in 2082 days


#2 posted 1487 days ago

Very nice job, good use of old tools.
I have a couple old stanleys laying around that may just be on the list

-- Doug...

View OttoH's profile

OttoH

844 posts in 1606 days


#3 posted 1487 days ago

Wow! That is a gorgeous plane you have made for yourself. It looks like it would be quite comfortable to use.

Great Job!

-- I am responsible for how I respond to everything in my life - - Deadwood SD

View canadianchips's profile

canadianchips

1831 posts in 1593 days


#4 posted 1487 days ago

Very Very nice.

-- "My mission in life - make everyone smile !"

View Bob A in NJ's profile

Bob A in NJ

1145 posts in 2595 days


#5 posted 1487 days ago

Very clever indeed.

-- Bob A in NJ

View swirt's profile

swirt

1935 posts in 1568 days


#6 posted 1487 days ago

Very nice. Are you sure that was a Stanley knockoff. It looks like it was a Stanley Handyman not that it had any value…it looks plenty valuable now. Great work.

-- Galootish log blog, http://www.timberframe-tools.com

View Richard 's profile

Richard

387 posts in 1717 days


#7 posted 1487 days ago

That looks like a plane I can use. It looks inviting to the touch and I bet it would suite its purpose well.

-- Richard Boise, Idaho

View michelletwo's profile

michelletwo

2187 posts in 1611 days


#8 posted 1486 days ago

CLEVER & resourceful.. use it with joy!

-- We call the destruction of replaceable human made items vandalism, while the destruction of irreplaceable natural resources is called development.

View marcfromny's profile

marcfromny

45 posts in 1955 days


#9 posted 1486 days ago

I’m so glad I found these pics! I’ve been wanting to do that for a very long time, maybe now I’ll attempt it. Great job!

View YorkshireStewart's profile

YorkshireStewart

1106 posts in 2497 days


#10 posted 1486 days ago

What a superb idea – beautifully executed Adam. Thanks for sharing it.

-- Res severa verum gaudium - True pleasure is a serious business. http://www.folksy.com/shops/TreeGems

View mafe's profile

mafe

9430 posts in 1685 days


#11 posted 1486 days ago

Hi Adam,
Thats really a wonderful job you have done. I’m deeply impressed.
Can you tell me what the advantage of a infill plane are compared to a ‘normal’ no.4 plane?
Best thoughts, and deep respect,
MaFe

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

View falegniam's profile

falegniam

333 posts in 1548 days


#12 posted 1486 days ago

for one who doesn’t like to work with metal, you do a very nice job.

-- If you work you eat - If you don't work, you eat, drink, and sleep.

View Don Alexander's profile

Don Alexander

14 posts in 2285 days


#13 posted 1485 days ago

I second that! Your metal work is beautiful and I wouldn’t even attempt that!

-- Don Alexander, Jacksonville, Florida

View Adam's profile

Adam

79 posts in 1658 days


#14 posted 1485 days ago

Mafe, some of the advantages are Mass. Tight mouth. Thick iron. Solid bedding. 55-degree bed angle for gnarly grain and it Looks cool.

-- Adam, St. Catharines, Ontario, Canada

View Kent Shepherd's profile

Kent Shepherd

2697 posts in 1882 days


#15 posted 1462 days ago

Impressive!

-- She thought I hung the moon--now she just thinks I did it wrong

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