The following photos show the steps that I take to build a typical infill plane.
254 Thompson Avenue
Louisville, KY 40206
(423) 471-0139
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Rough cut stock
My planes are made from flat stock… not castings. The alloys are 303 stainless, 360 brass, and A2 for the blade.
Stock Milled
Pieces now have square edges and are milled to the precise length.
Surface Grind
303 alloy stainless has a rough, pitted surface. I, therefore, surface grind the stock.
Marking
After applying layout fluid, I plot where the drilling and tapping needs to happen.
Initial Drilling and Tapping
These are the essential connecting points. All other connectors are important, but have a “fudge” factor.
Beveling
The sole plates are beveled at 50 degrees in the rear. 40 degrees at the toe. Unlike tradition infill planes, my blades rest entirely on a metal surface… not wood. That’s why the slug of brass is incorporated.
Initial Shaping
All the elements are roughly shaped, before further drilling and assembly.
Assembly
The carcass of the plane has now been stitched together with counter sunk screws and dowel pins, forced into undersized holes
Refined Shaping
The sides have been ground flat, the nose beveled, and the sides beveled. Other than the surface grinder on the sides… no magic, here. Lots of file work.
Sole Flattened
And now the fun part… flattening the sole. Sandpaper on a stone… and soul crushing.
The Blade
I use A2 steel. You buy it in an annealed “soft” form. Meaning you can mill it, file it… whatever.
Carbon to Knife
No way I’m getting into the nitty gritty of knife making, here. I would just say that it’s a well published discipline, formulaic, and, with modest gear… totally doable.
Sharpened
I send my planes out with flat backs and a razor’s edge.
Turnings
The little bits that make it work.
Wood
Pieces fitted. I’m talking to woodworkers, so I don’t have to explain this to you.
Pretty Wood
Wooden bits are shaped and finished. I use shellac.
The plane! The plane!
This was a gloss-over about the process… but, you get the gist. BTW. This plane kicks ass.
Glamour Shot
