Bedrock 603 re-animation #2: Body Repair

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Blog entry by thetree posted 05-04-2012 10:53 PM 4350 reads 0 times favorited 8 comments Add to Favorites Watch
« Part 1: Unearthing Part 2 of Bedrock 603 re-animation series Part 3: body rework #2 »

Here I will explain how I repaired the main crack in the body. Actually, It is more of a repair of a horrendous repair job. Here is a good view of what I was working with:

Sandblasted view of the “repaired” section:

Sawcut through old repair:

Layout of section I need to replace:

Milling section to be replaced:

While I had one side open, I figured I would take the time to straighten up the front of the mouth.
As I said, the mouth was considerably squeezed closed at the side with the repair, and it appeared that the handyman who was using this was having considerable trouble with the use of the plane, so he filed it to allow chips to pass, but it was mostly rounded off and terrible looking:

I knew I would open the mouth a little by doing this, but it seemed like the lesser of evils so I set it up on 15 degrees, and walked an endmill down the front of the mouth to make it near sharp. I ended up with a radius runout at one end but I will be able to file that out easily.

Here I am working on making the cast iron replacement piece:

I purposely made it wedge shaped because I knew I would have to tweak it open a little to make the front edge of the mouth square with the sides and it worked smoothly. I was slightly worried it would move during braze but the flux seemed to hold it during braze and it didnt move:

Silver brazed:

Cleaned up:

I am happy with how it came out. The braze lines are going to be much less visible when it is all said and done. I will be surface grinding the body on 3 sides in my next post, finishing the profile to match the existing one, and dressing up the inside. Not bad for just under 3 hours work….

Thanks for following. More in a few days….


8 comments so far

View SamuelP's profile


755 posts in 1735 days

#1 posted 05-04-2012 11:04 PM

Fantastic Job. Can I send a plane to you that would be a real challenge?

-- -Sam - Tampa, FL- "A man who carries a cat by the tail learns somthing he can in no other way" -Mark Twain

View Smitty_Cabinetshop's profile


12276 posts in 1708 days

#2 posted 05-04-2012 11:21 PM

Totally amazing! I’m ready for the next post!!

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive

View ShaneA's profile (online now)


5836 posts in 1688 days

#3 posted 05-05-2012 12:02 AM

Wow, looking a lot more refined. Well done so far…a real save.

View MedicineMan's profile


106 posts in 1557 days

#4 posted 05-05-2012 01:24 AM

Great job! I love to see someone take a fine old piece of equipment and remake it into a very useful tool. You got a good plane to be proud of.

View russde's profile


94 posts in 1929 days

#5 posted 05-05-2012 10:51 AM

And here I was proud of myself for soaking in evaporust, painting, and sharpening.
Heck of a job!

View Don W's profile

Don W

16822 posts in 1657 days

#6 posted 05-05-2012 11:54 AM

that’s some talented metal work. Nicely done!!

-- Master hand plane hoarder. -

View Dennisgrosen's profile


10850 posts in 2204 days

#7 posted 05-05-2012 01:30 PM

looking good sofare :-)
you have the skills for it
have you considered to weld it instead


View thetree's profile


17 posts in 2093 days

#8 posted 05-07-2012 12:27 PM

I can’t remember ever seeing a decent weld job on cast iron. Especially when you have to get close to a thin edge. It would be an even worse idea in this case because the last “repairman” decided to remove material from the crack with some kind of grinder. You would either have to patch it like I did and have 2 welds, or try to bridge it and get a fill of some kind. The next post should be coming in the next day or so.


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