It is always tempting to rush off to the next stage, like the bottoms. But once the side profiling is complete there are still quite a number of other operations to be completed and these sides just scream to be finished. The polishing of the sides is a major undertaking and it eats up a lot of my time.
I use four abrading grades and at each stage everything is continually blued which helps me avoid any form corruption.
With a few purpose made spacers I am able to keep the edge polishing true and sharp without any deformation.
It could be embarrassing to mention how much time this operation takes but if perfection is required …..
These sides are now waiting for stamping and another surface grind on the inside faces, for its final texture.
Despite having some part made infills which had been drying for 20 years, I decided that I preferred this piece of rosewood (which has also been in my workshop for a long time, and I have very little left) – Dalbergia Cubiquitzensis – it has more ‘bling’
I am in the process of making a small batch of these planes, which will include this rosewood, Boxwood and a mystery wood – photos soon.
Progress on my A28 Chariot Plane
This picture shows some idea of all the work that goes into this plane. Unless you have done it yourself you can never imagine the effort and thought that goes into making this Chariot. This plane is made to a standard light years beyond its original counterpart made by Norris.
Blades for the Bullnose plane
Cutting the blade bevel
The blade is secured by its adjusting holes etc, in a purpose made holding block, for profile milling.
The milling is coming to an end of the first cut.
The finishing cut.
Profiling complete, with just the side bevels to be done. This is a quick summary of some of the blade work.
A picture of the main components ready for assembly. It has been a long time getting here. It is just like climbing a mountain – you keep seeing false summits.
This is one of only six A27 Bullnose planes I made many years ago. This was made by casting as were the original Norris. There were one or two downsides to this method of production so for some time I have been contemplating making a fabricated version using traditional dovetails. Now that time has arrived. It will be a limited edition, and as you will have realised I am moving away from traditional infill planes so unlikely that I will make these again. This is the second plane in the set of three low angle planes I have been making for some of my customers – A27, A28 and A31.
A quick line drawing of the proposed plane. This is being made with naval brass sides (CZ112) and malleable cast iron for the bottoms, fore-end and bridge sections. I will be using a traditional wooden wedge and the adjuster housing is also rosewood. To my knowledge a Bullnose plane has not been made since Norris’s time in the 1920s – when it cost 23/- (shillings). I shall have to charge a little more. I have also moved the goalposts in regards to quality and precision.
The sides being routed on the CNC mill. All the precision work holding tools and jigs I made myself before starting this. Every plane I make has individual jigs and work holding which are surface ground to a high precision. My tool room has been built up over many years and is, I believe, the only one of its kind. You will not find this standard of precision anywhere else.
The riveting holes, include a 60 degree chamfer, which provides the jig fixing and positive location.
The mouth being cut out last as a separate job as it needs an additional clamping to support the front end – which can be seen to the left hand side of the picture.
Here is the finished side except for the dovetailing. It includes its mirror partner completing the pair.
As usual to be continued when I next have an opportunity.
Selected wood for my next project – A31 thumb plane (probably the last batch)
Best part of the metal work well on the way
No 10 smoother/mitre
A very patient customer asked me to make a small mitre plane. He wanted a 11/4” wide blade to be bedded at 25 deg and bevel up with a short body. No adjuster was required.
I would classify this plane as a smoother/mitre. The small mitre plane has always seemed to be surprisingly scarce for its usefulness. Having got my simple sketch approved the first batch is now well on the way (the sketch can be seen on the website here http://www.holteyplanes.com/).
It is a combined stainless steel bottom with naval brass dovetailed sides and brass lever cap and thumb screw. The blade is in my A2 original specification and has a top sneck. The length of the plane is 43/4“.
Despite its apparent austerity there will be no lacking in specification and quality. The designation will be No.10. Delivery will be end of November 2011.
What better place to start than the blades. Here are the A2 blanks being drilled and shaped. These are now away being heat treated (the only work to be done out of house).
Brass sides have been cut from sheet and trued up into rectangular blanks.
The final part of the A6 construction.
Drilling and countersinking frogs for the rivets.
The bottom has been slotted out for mouth and drilling for the corresponding frog rivets.
Adjuster components for A6
This item is most commonly known as the banjo and it is the most work intensive component in the whole plane. This picture shows that it comes out of a round bar.
There is a lot of preparation but this is not a step by step instruction manual, it is just a few snapshots. In these pictures, after lots of preparation I start to ball generate the round part of this component.
A6 Part 2
All of the woodworking has its edges squared up on the milling machine as I have a bit more confidence in this machine than I do a planer.
A pair of infill sides being drilled for riveting spacers. At this stage all edges are trued up
This is the infill side with the spacers pressed through the handle testing for fit. The two sides have yet to be separated.