Inspired in one Paul's Sellers collection hand planes, I decided to make my own one as similar as possible in an easy way and using hand tools. In this video you can see the step by step.
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I would also apologise for my English as a non-native English speaker some terms are very difficult for me. Forward, inscrutable!!
Step 1: Materials and Tools
- Sycamore wood
- Quality Brass sheet (1,6mm/0,06") thickness
- Insert rivet nut (M6) 0,35" Amazon USAUK
- Blade plough plane (10mm/0,39")
- Sapeli dye and Wood wax
- Thumb screw
- Hand plane No5 & Block plane
- Engineers Square
- Gauge Veritas
- Japanese Saws
- Angle Level and ruler
- Veritas Dovetail Saw
- Rasps and Files
- Gouge cut 3 straight
- Sanding Paper grit 250
- Fret saw
- Cabinetmaker’s Hammer
- Electric drill and Bit drill (9mm) (0,35")
Paper joining tape
Step 2: Cutting the Main Piece
For this project I used Sycamore wood since this is a resistant and hard kind of wood. I have made it, as almost always, hand tools but you can replace them by power tools.
I began cutting one side of the wood and planing it with a hand plane. Once straight with the help of a gauge I marked the rest of the parts to cut. I repeated the previous steps in order to obtain a completely square wooden block.
Step 3: Marking and Cuttings
We have to mark an angle between 45 and 50º as per photographs and we cut it wihout reaching the end.
Then clean the saw-toothed marks leaving a smooth and plane surface.
Step 4: The Blade
With the help of a ruler mark the centre of the piece and introduce the blade that we'll use for our router plane. In my case I used an old plough plane blade of 10mm/0,39". Mark the contour and eliminate the wood where we'll introduce the blade with a chisel.
Step 5: Cutting
Now we have to cut a wide enough surface to see the blade path when we're working. I chose triangular shape but it can be used any other shape.
Step 6: Oval Shape
In order to give the router plane a more ergonomic shape, I give where the thumbs will be supported rounded shape with the help of gouge cut straight
Step 7: Lever Cap
Now we have to make the lever cap which will hold the blade. I make a template with the help of paper joining tape and later I glue it on a brass plate. Cut the piece and file down the edges until it's smooth.
Step 8: Drilling the Brass
I drill 4 holes for the fastening screws and another one of 9mm/0,35" in the middle for the rivet nut. As I don't have the necessary tool for the rivet nut, I use for it a hammer as you can see in the video.
Step 9: Coating and Final Assembly
For the wooden finishing I use Sapele dye and wax.
Now the only thing left is to screw the brass plate, to introduce the blades, set the ploughing depth and to start working!!