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Wooden router plane

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Project by yuridichesky posted 11-24-2013 10:42 PM 3468 views 41 times favorited 68 comments Add to Favorites Watch

Tool-making bug is itching me. Earlier I said that I needed router plane for my workbench build, but what the hell, I just wanted to own one. Honesty is the best policy :-)
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Here is my starting point: cutter with threaded rod and milled facets:

Since I had no “real” cutters available here for any reasonable money, I needed to make one from scratch. On one hand I didn’t like usual option – L-shaped hex wrench, and on the other hand I wanted some adjustment facilities, so I came up with this solution: to weld tip of the chisel to the threaded rod (10mm diameter). The idea was to minimize number of parts involved into design, and since I had to make the cutters anyway I decided to give it a try. This was the most expensive part of the project: 6 chisels (4mm, 5mm, 6mm, 8mm, 12mm, and 16mm), plus metal turning, milling, and welding work (that I had to outsource) took me about $80. I don’t know how chisel tips were welded, I just asked guy who did it for me to try not to overheat cutting edges. Will see how my cutters gonna hold the edge. Also I spent quite a bit time truing up cutters geometry, but thanks to DMT stones it wasn’t too bad.

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Having cutters ready I made a bolt that holds the cutter:


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The adjustment nut had to be re-shaped slightly, so I employed my poor-boy lathe, this time cutting brass with sharpened tip of the file:

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Next I made a prototype out of pine:

The prototype was very right thing to do, it let me to test all my not-so-good ideas before I found something that would work for me.
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Next was plane body (beech).


(Main hole drilled with the help of sacrificial piece of wood. The drilling is still my weak spot, I guess I need a drill press.)


(Templates like this one was another right thing to do.)

Ready for shaping:

And here the shaping starts:

Checking shape against the template.

Here’s my favorite one: prototype is being used as a tool to build a tool it’s been prototyped for:

Sanding.

Two brothers:

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Brass work.

Brass stripes glued into cutter-mounting hole to protect wood from wearing:

Back side of adjusting nut cover plates and back washer:

You can see that I had to hammer brass parts to adjust their shape for better fit. Turned out that metall allows for some errors as well as the wood.

Bolts’ heads re-shaped from hex to round:

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Handles.

Handles turned on my poor-boy lathe from some unidentified wood from my mom’s garden.

One ready and one more to go:

Final shape of the handles: more smooth curves to match plane’s body:

Reaming handles with some ugly bit made from bolt:


Despite its ugliness it provided perfect recess for the head.

Drilling holes for the handles.

Here’s how I made little recesses for the handles: I glued sandpaper at the bottom of the handle, screwed it in place and kept rotating it until it cut its way down in the plane’s body. Then removed the sandpaper.


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All parts in place, ready for finish:

After two coats of danish oil:

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And finally some tool porn for the brave who survived such long post :-)

Plane in action:


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Couple of words about how adjustment works. It works great! I think adjustment machinery is quite clear: you turn adjustment nut which is locked in place with cover plates, the adjustment nut pushes/pulls the cutter up or down. The threads on the rod/nut is 1mm step, so one full turn of the adjustment nut gives 1mm (a little more than 1/32”) of cutter move. So if I need to go 0.25mm down I do 1/4 turn and so on. Cool! And this little dot on the adjustment nut helps me to track cutter move:

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Thanks for stepping by, being a happy owner of the router plane now I’ll be happy to answer any questions about one :-)

-- Yuri (10x4 -- yeah, that's my tiny shop!)





68 comments so far

View slapdash's profile

slapdash

58 posts in 880 days


#1 posted 11-24-2013 10:49 PM

Wow! that is so flash. Brass inlay too. Does it work? I would love to have a gadget for cutting grooves but this might be beyond me.

-- I'm not creative, I'm just bad at copying

View yuridichesky's profile

yuridichesky

315 posts in 620 days


#2 posted 11-24-2013 10:54 PM

Slap, thank you! It does work! Hell yes! Now I’m counting each and every little scratch on plane’s sole after each pass :-)

-- Yuri (10x4 -- yeah, that's my tiny shop!)

View Don W's profile (online now)

Don W

15032 posts in 1223 days


#3 posted 11-24-2013 11:06 PM

sweet!! I love the poor boys lathe.

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

View lepelerin's profile

lepelerin

321 posts in 981 days


#4 posted 11-24-2013 11:07 PM

Really well done, Tx for all the pics.

View yuridichesky's profile

yuridichesky

315 posts in 620 days


#5 posted 11-24-2013 11:09 PM

Don, thank you, I realize I use my “lathe” more and more often, so I start thinking about some scaffold to ease mounting it on the benchtop.

-- Yuri (10x4 -- yeah, that's my tiny shop!)

View hoss12992's profile

hoss12992

2752 posts in 549 days


#6 posted 11-24-2013 11:17 PM

That is really cool, thanks for sharing

-- The Old Rednek Workshop https://www.facebook.com/theoldrednekworkshoptn

View yuridichesky's profile

yuridichesky

315 posts in 620 days


#7 posted 11-24-2013 11:18 PM

Lepelerin, thanks a lot!

-- Yuri (10x4 -- yeah, that's my tiny shop!)

View yuridichesky's profile

yuridichesky

315 posts in 620 days


#8 posted 11-24-2013 11:20 PM

Hoss, thank you. Hope long post won’t scare visitors off.

-- Yuri (10x4 -- yeah, that's my tiny shop!)

View Vagabond55's profile

Vagabond55

81 posts in 1915 days


#9 posted 11-24-2013 11:30 PM

Beautiful !!! I wish I could have this sort of woodworking skills…

View Boatman53's profile

Boatman53

839 posts in 852 days


#10 posted 11-24-2013 11:35 PM

Very nice Yuri. That is on my build list soon and I am going to honor you by using some of your details, but I think I’ll but some cutters. Thanks for posting.
Jim

-- Jim, Long Island, NY Ancorayachtservice.com home of the chain leg vise

View HillbillyShooter's profile

HillbillyShooter

4601 posts in 948 days


#11 posted 11-24-2013 11:49 PM

Outstanding project and very nice write up with great pictures. Thanks for sharing.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View CL810's profile

CL810

2017 posts in 1644 days


#12 posted 11-25-2013 12:01 AM

Masterfully done Yuri! Favorited. Great post.

So now you have everything to finish the bench. Right?

-- "It's amazing how much can go wrong when you think you know what you're doing."

View waho6o9's profile

waho6o9

4926 posts in 1233 days


#13 posted 11-25-2013 12:02 AM

Outstanding build Yuri! I see a a Daily Top 3 award in your future.

Thanks for a great pictorial and you were wise to build a prototype

first. Gotta keep that in mind.

View Rick's profile

Rick

6454 posts in 1689 days


#14 posted 11-25-2013 12:15 AM

Very Nice Work Indeed! Thanks For Posting!

Rick

-- COMMON SENSE Is Like Deodorant. The People Who need It Most, Never Use It.

View theoldfart's profile

theoldfart

4251 posts in 1107 days


#15 posted 11-25-2013 12:31 AM

Yuri, have you noticed CL810 has been strutting a bit lately ? Must be close with that bench thing of his :0)
That is a masterful tool you’ve created. Well done.

-- "Aged flatus, I heard that some one has already blown out your mortise." THE Surgeon ……………………………………. Kevin

showing 1 through 15 of 68 comments

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