By Mark Webster
Part 1 (08/01/2020)
The following is an outline (sorry a little cryptic) from a 2-part presentation I made recently on the Facebook page A Plane Life https://www.facebook.com/APlaneLife.us/ The two “informal” sessions are included in the posted videos. They are long, but if you have the patience I cover all of what is in this outline.
My planes
I do this as a HOBBY, I am not a machinist and don’t have machinist’s tools
Starter planes not for collectors
Goal
High performing
Well taken care of… but not “brand new” looking
Getting starter planes.
I look for Types 6-15 prefer Types 9-15
Avoid:
Hairline crack on sides, or at ends of throat toss
Deep pitting
Pitting on back of iron
Reasonable thickness on sides allows cosmetic adjustments
Shipping is often much higher than necessary and a killer.
When Plane arrives
Save packing material
Inspect for hairline cracks sides and mouth
1 Showing rip at mouth https://www.instagram.com/p/CAfxM1PjYY-/
Microscope or penetrant testing
Correct parts for Type?
GENERAL CLEANUP
Removing Rust dirt and Paint/Japanning
Electrolysis
Evaporust
Wire wheel
Bead blaster most efficient
Harbor Freight floor standing blast cabinet. It has been upgraded using
2 Tacoma Co upgrade kits https://www.instagram.com/p/B_1Us6Cjw9m/
I have installed foot pedals for light and vacuum
Frog and Body
Stripping using bead blasting cabinet
No7 glass bead
150G fractured glass.
<= 40 lbs pressure
Pre-scrape if difficult
½“ chisel (sharp and careful not to scratch with corners.)
Avoid areas that will not be painted with 150G and higher pressure.
Follow w/ No 7 glass bead 20-30 lbs
Soften painted surfaces, and de-rust / clean all areas
3 Showing stripped bodies https://www.instagram.com/p/CBj13gcjx2x/
Unpainted larger parts:
Lever cap, iron, cap iron
20-30 lbs No 7 glass bead – de-rust and clean
Wire wheel after
4 Completed parts after blast and wire wheel
https://www.instagram.com/p/B_z-R1fjfT-/
Small parts –
5 Holder with threads https://www.instagram.com/p/B_5FOWLDi1x/
Helps clean screw slots
20-30 lbs No 7 bead
Fine wire wheel also wire cone
Machined surfaces
Posts for wood,
vice grips for small post and hold large post in hand
brass nuts held on large post
Screws
Do tops with plyers then flip and vice grips holding tops to do threads
Horseshoe clip and washers
plyers
Brass depth adjuster
Low pressure glass bead to clean or walnut shells
“Jig” Special threaded rod and steel nut, and hand drill
6 Showing knobs and “jig” https://www.instagram.com/p/B7kYXPjnZSl/
7 Fixture in action https://www.instagram.com/p/B7kYgHiHke-/
8 Applying Brasso https://www.instagram.com/p/B7kYy4EnrOI/
9 Applying Brasso https://www.instagram.com/p/B7kY3dcHEzz/
10 0000 steel wool and abrasive wheel on drill (not using cloth any more) https://www.instagram.com/p/B7kZUcbnyjz/
11 Spinning away https://www.instagram.com/p/B7kZZAQn7Ah/
12 Paper towel to clean and buff https://www.instagram.com/p/B7kZrgFHwYJ/
13 All done https://www.instagram.com/p/B7kZvsfncDv/
14 All done https://www.instagram.com/p/B7kZzsgnjQO/
MASK AND PRIME BODY
Priming only here
Prevents rust during refurb process. Newly exposed metal can rust quickly.
Avoid damaging final finish
Frog primed later
Minimize Frog washer damage
Rust less likely on the frog
Will describe masking, primer and finishing techniques later
INITIAL FLATTENING OF PLANE BOTTOMS
Modified Belt sander
15 Showing modified Sander and lapping plate
https://www.instagram.com/p/B97EN5-g5_G/
Modified the platen
Graphite removed
3/16” glass
carpet tape fiberglass
Belts
Zirconia alumina
Norton Blaze coral ceramic 60G
Best belts
Zirconia 15 min
Blaze 50 min
Write # of minutes used with Sharpie on belt to keep track how long used
Pressure helps on Zirconia and ceramic belts
60G 80G and 120G
Dust control
Foot pedal
Prevents dipping
16 Foot pedal and general setup https://www.instagram.com/p/B97KQ0ugmNQ/
Foot pedal to control on and off
220V discussion
Initial flattening process
Frog attached (to pre-flatten and lap)
17 Showing effect of frog paws pushing down when tightened.
https://www.instagram.com/p/B97PVwcgkic/
Plane on belt – foot pedal on
Cover entire belt, plane parallel long axis
Diagonal NO
Warming up… peddle off
THEN remove plane. Reduces dips
18 Showing plane on sander https://www.instagram.com/p/B97Mhr3gDO0/
Safety risk using Pedal
Don’t over heat
Rotate bodies
Table saw heat sink
Clean up Plane sides
Need enough material
90˚ sides? get a shooting plane. Originals not really 90˚
120G Zirconia
Final hand sand
CRC 3-36 to paper towel then plane
PRECISION LAPPING
Setup
Lapping Plate
Granite flat
3/8” glass
Aluminum on glass
Make sure your flat
Precision straight edge
Support surface for the plate. Shims?
Sandpaper
3M Stikit Gold
Best but expensive
Easy removal glass or granite
Klingspor
Cheaper
Glue too aggressive on glass or granite
| Length | 80G | Cost w | Cost | ||
| Yrds | Price | shipping | Shipping | /Yrd | |
| Klingspor retail | 10 | $10.95 | $7.99 | $18.94 | $1.89 |
| 3M Stikit Gold | 25 | $52.96 | $0.00 | $52.96 | $2.12 |
| Norton Gold | 25 | $28.99 | $4.99 | $33.98 | $1.36 |
| Porter Cable | 10 | $12.99 | $0.00 | $12.99 | $1.30 |
$0 shipping is with Prime
I have not used Norton Gold or Porter Cable.
Links for the sandpaper above:
Klingspor
https://www.woodworkingshop.com/search.aspx?q=AR51344
3M Stikit Gold
Norton Gold
Porter-Cable
Mods to allow using Klingspor
19 Lapping plate set up https://www.instagram.com/p/B8FJekzAgUD/
Klingspor is manageable on aluminum + paste wax
Paste wax aluminum every other strip.
3/8 Glass + ¼” aluminum plate 4” x 36” https://www.midweststeelsupply.com/store/6061aluminumplate $37 with shipping
Carpet tape
Flat support surface
Confirm flat
Precision straight edge
Reverse lapped aluminum No 7 LN + 3M Stikit
Confirmed end point with precision straight edge and 0.0015” feeler gauge
Cleaned No 7 afterwards 😃
Lapping
20 Showing actual lapping https://www.instagram.com/p/CAjnVgBD6SZ/
Sharpie Grid pattern on bottom PENCIL may be good alternative still evaluating
80G 5 sets of 30 laps
After 30 use magnet remove iron grit
Once flat 120 180 (220) grits. Scotch-brite Maroon pad
Fine file sharp edges then 220G
CRC-3-36
FROG PART ONE
Loose lateral adjuster Fix
Jig
21 Shows detail of jig and basic use https://www.instagram.com/p/B8zrgpnAdcT/
Tune bedding surface for plane iron
Sandpaper and granite flat
22 Shows process of lapping https://www.instagram.com/p/B9C5xn4Agr1/
Will come back to frog later
Need tuned iron first
PLANE IRON
Flat?
hammer tap on ¾” birch ply or twist it straight in vise. Parallel clamps
Verify flat on granite flat
Pre-flatten back
Flat and damage free
120 G on sander w/ glass platen
Jigs for this
23 Jigs for initial flattening on sander https://www.instagram.com/p/B7oZDyCHJR_/
24 Getting ready to present iron to sander https://www.instagram.com/p/B7oZKKfnhAW/
25 Jig on the sander https://www.instagram.com/p/B7oZPkvHEGk/
Procedure
Place jig/iron
Foot pedal on run few seconds
Foot pedal off
Once stopped remove iron.
This avoids dip
Rotate the irons so they will cool between bursts of sanding.
26 Initial flattening complete https://www.instagram.com/p/B7oZagRHqNA/
Square iron and add new bevel
Flatten reference side of iron before marking right angle
27 Shows from making a reference edge to grinding bevel https://www.instagram.com/p/B9x4WMmgUDP/
Mark 90˚ from Reference side low enough to remove damage and old bevel
Oneway Wolverine grinding stands (versus Veritas)
Steel not aluminum (wear)
More stable
Bevels
01 25˚ primary and 30˚ secondary
A2 and PMV-11 25˚ or 30˚ primary and 33˚-35˚ secondary
28 Showing Geiger’s Tru N Dress https://www.instagram.com/p/B8rkJSNAIKD/
FROG PART TWO
Does the frog sit properly?
29 Shows jig and checking for improper bedding angle https://www.instagram.com/p/CAq1njCjCOY/
Skewed iron with everything centered
File new bedding angle on frog bottom
Frog needs to be lower on the side where the iron is projecting less
Jig used to keep paws co-planer to rear machined flat Types 9+
Procedure
30 Shows filing frog and resulting correction https://www.instagram.com/p/CAq4QBFjfQi/
Set up jig adding shims to bring sandpaper to touch paws that establishes original relationship between 2 planes. (Not hand planes here) ha ha
Sharpie the machined flats
Using parallel clamps file lowering appropriate side on the flats
Clean up rear flat on granite flat with 80 grit
Use jig to finish paws
Recheck in plane
repeat until iron projects evenly
31 Shows diagram for jig https://www.instagram.com/p/CArc4t5j32F/
DO NOT OVER TIGHTEN FROG SCREWS
32 Shows plane cross section https://www.instagram.com/p/CBUB5cMD5mW/
FINISH THE IRON
Final flatten back
33 Shows flattening on granite flat to 320G https://www.instagram.com/p/B9w44Qmj8LW/
Lap at 80G or 120G until flat, sharpie
Single direction lapping
Once flat 120, 180 220, 320 removing scratch patterns for each.
Polish the back
On freshly flattened stones.
34 Moving through the stones https://www.instagram.com/p/B9xAkNsAMHw/
Lap both directions keep flat
Go through thought 1000, 1200, 2000, 5000, 8000. Removing abrasive patterns of previous grits.
1200 and 2000 are added here to speed process, not used in daily sharpening.
Back should not touch earlier stones once polished unless there is damage.
Final primary Bevel
35 Finetune primary and hone secondary bevel https://www.instagram.com/p/B9x9LHXAp8D/
To control getting a straight uncambered edge
36 Showing problem w center wheel guides https://www.instagram.com/p/CBPotIYDpuw/
Avoiding wheel track to insure flat edge
37 Showing solution for center wheel (reusing lapping sandpaper here) https://www.instagram.com/p/CBPnPFzDUXR/
38 Showing a nice secondary bevel https://www.instagram.com/p/B7hsIFpHUgx/
Camber or no camber
I don’t follow traditional philosophy about fine tuning or not based on plane size. I highly tune all the same.
Minute camber on No 5 and smaller. No camber on 6 and up
I use Chris Schwarz’s method for cambering. See at end of this document.
TUNING THE CAP IRON
39 Showing tuning the cap iron https://www.instagram.com/p/B9yDceOjlai/
SET UP PLANE AND TEST
If plane is performing well… then final mask and paint
MASKING AND FINISHING
Wash and rinse primer— washing soda
Blow completely dry
40 Showing washing https://www.instagram.com/p/CCPXOP1jI3m/
Masking
Single edge razors
#11 blades for X-Acto knives
Tweezers
Scissors
Scotch Blue Original masking tape, ½” ¾” 2”
Masking pre-Type 9
41 Show technique for frog flats https://www.instagram.com/p/B79CLtCg4jK/
Masking Type 10 and later
42 Technique frog top https://www.instagram.com/p/B79VIqpAMeb/
43 More https://www.instagram.com/p/B79Tnc2AY3_/
44 Technique frog bottom https://www.instagram.com/p/B79U2Z1ghMf/
45 More https://www.instagram.com/p/B79UaS0gmv7/
Masked bodies
46 Eye candy masked bodies https://www.instagram.com/p/B77pJYmgi2h/
Masked frogs
47 Eye candy masked frogs https://www.instagram.com/p/B7fRhEoHHVN/
SPRAYING
Turn-table easier
48 Showing video of using turn table during spaying a coat of primer https://www.instagram.com/p/CCcoNmjDMRB/
Prime frog (hand held) Flop the Y adjusting lever back and forth
Mix cans of matt 3 mins (or greenish)
1 coat Primer
2 coats Matt Black
1 coat Matt Clear
30-60 mins between coats
Remove masking 1-2 hrs
Next day remove paint from top edges of sides
Cure 2 weeks
Finishing materials Links
Primer
Matt Black
Matt Clear
Part 2 (07/25/2020)
From last week
Reference for Screw sizes
Victor Machinery is now Wholesale Tool the old phone # will work 800-723-5359
Lever cap screw 9/32-24 Tap #0307-1015,
They don’t sell die
Here is place in Canada
https://www.newmantools.com/price/taps_ns_pr.html
Cap iron Screw 5/16-18 Tap #0329-0041
5/16-18 Die #0535-0115
Brass adjusting nut LH 9/32-24 die and tap
They don’t sell, I had mine custom made from Tapco
Frog screws 12-20 Tap #0307-0796 They have 200 on B.O since Jan
12-20 Die #0536-0086 They have 200 on B.O since Jan
Frog adjusting screw 1/4-24 Tap #0307-0003
1/4-24 Die #0504-0185
Handle toe screw 12-20
Handle and knob bolt 12-20
Frog adjusting plate 7/32-24 Tap #0307-0915
Screw 7/32-24 Die #0504-2570
Some feel you can use 7/32″-20Tpi Whitworth form instead of a 12-20. I have not tried it.
Discuss camber
Chris Schwarz’s method at bottom of this document.
No 3,4,5 very minor
No 6,7 no camber
Finishing:
Spraying frog…. flop Y back and forth
Removing tape in a couple of hours so not brittle
Pre-flattening
Writing time used on belts with sharpie
Keep track of belt use
Hand lapping:
Spay blue vs sharpie vs pencil
Another sandpaper thanks Sean updated above comparison.
Rhynostick 80 Grit. $1.08/Yrd including shipping
Good price
Trying… ok so far
Grinding wheels
Norton 3x blue 80 grit
Inserts for grinding wheel
https://www.woodturnerscatalog.com/p/97/6196/raptor-R3X-Grinding-Wheel-Bushing-2-Piece-Set
Grinding at 90˚ to reduce length of iron
Holding machinists squares to evaluate the end of the cutting iron for squareness
Structural Difference between planes Type 8 and earlier versus Type 9 and later (Cut away side views)
Showing how frog interfaces to body
49 https://www.instagram.com/p/CC2tdSnD4Az/
50 Tapping out the pin and repairing a lateral adjuster https://www.instagram.com/p/B80R3z0gnKI/
Classic view of plane size and level of fine tuning. All mine the same.
Microscopic views of cutting edge after using sandpaper
51 https://www.instagram.com/p/CC9BmbyDlLg/
Side view of frog, iron, cap iron and lever cap showing pressure points
52 https://www.instagram.com/p/CDA85ZoDP6v/
How long does it take to hone frog bedding surface
53 https://www.instagram.com/p/CDB-01ejeMO/
Discussed method for removing depth adjuster bolt.
Could sacrifice a nut shorten and split.
Loctite, (heat if have to remove)
TOTES AND KNOBS
Strip w/ lacquer thinner and maroon Scotch-brite pads wear gloves
Cracks partial breaks …. finish the break
Glues
54 Oily wood epoxy for areas to receive stress
https://www.instagram.com/p/B7hFPKLnp-R/
http://www.glueoakandteak.com/
2 Ton Epoxy for lower stress like replacing tops
5 min for cosmetic
Mix with rosewood dust if gaps
TOTES
Severely broken tops
55 Eye candy of broken tops https://www.instagram.com/p/B7fSDsNHehK/
Remove tops on table saw (safer on bandsaw)
Base against fence
Cut at front point
56 Eye candy tops removed https://www.instagram.com/p/B7fSHChHacc/
57 Matching color and grain for tops https://www.instagram.com/p/B7fSSjcHZwX/
I use Brazilian Rosewood if I have it, also Indian, Bolivian and Honduran. Turning blanks is a source 1.5”x 1.5 x 3” increments.
This wood is toxic wear breathing protection
58 Showing gluing on new tops https://www.instagram.com/p/B9mZegyD-0m/
59 Showing using patterns shaping tops https://www.instagram.com/p/B9nhI46g45c/
60 Eye candy lots of patterns https://www.instagram.com/p/B7hFCvGHtYV/
61 Showing making new hole for nut https://www.instagram.com/p/B9nqUUejHc3/
62 Showing drilling post hole and more shaping https://www.instagram.com/p/B9nuxwxDE65/
63 Showing more shaping sanding and filling https://www.instagram.com/p/B9o4yHADCUh/
64 Showing blending color and finishing adjusting nut https://www.instagram.com/p/B9pjKVDAayb/
65 Eye candy repaired totes ready for finishing https://www.instagram.com/p/B7fTSM9Hot8/
Clean Middle Breaks
Clean surfaces with lacquer thinner and brass brush
Glue with oily wood epoxy
66 Adding support dowels https://www.instagram.com/p/CAVsa1jjoCb/
Old or Ragged Middle Breaks
67 Showing Part 1 of repair….. patterns, removing section on bandsaw and gluing new section https://www.instagram.com/p/CCXjSdIjwK9/
68 Showing Part 2 of repair to completion https://www.instagram.com/p/CCXi6KCjal4/
69 Showing finished repair https://www.instagram.com/p/CCXmwIKDi2H/
KNOBS
70 Eye Candy Knobs completed https://www.instagram.com/p/B7fR790nLjN/
71 Shows Knob side repair https://www.instagram.com/p/B7_ivI1gVQU/
72 Shows splits in knobs https://www.instagram.com/p/B7hCH2tHL16/
73 Shows punch to split https://www.instagram.com/p/B7hCQAVnBAD/
74 Shows result of punch https://www.instagram.com/p/B7hCYN2nvHC/
75 Shows often multiple splits https://www.instagram.com/p/B7hCdzlnlIq/
76 Shows trimming acid brush https://www.instagram.com/p/B7hCk7XnAsI/
77 Shows taping multiple break https://www.instagram.com/p/B7hC6tUHyqZ/
Glue in a series of steps, break glue…break at next crack glue and so on
78 Shows using zip tie on multiple breaks. https://www.instagram.com/p/CCuFl2Pj7DM/
79 Shows clamping single break https://www.instagram.com/p/B7hDCmvnqjP/
80 Eye candy glued knobs https://www.instagram.com/p/B7hDWYgHgm1/
81 Eye candy knobs using paper with numbers to keep track of which plane each knob belonged to https://www.instagram.com/p/B7hDaeqHUly/
82 “Jig” for sanding knob https://www.instagram.com/p/B7hEHwKnZNJ/
83 knob mounted on drill press I use the lathe now https://www.instagram.com/p/B7hEOTlHOxD/
84 Lath set up for knob https://www.instagram.com/p/B7wS32nABAd/
85 Video knob sawdust “Black Hole Dust Catcher” https://www.instagram.com/p/B7wSsb_AaBC/
https://www.woodturnerscatalog.com/p/89/6387/hc-Black-Hole-Dust-Catcher-System
86 Aid for spraying knob https://www.instagram.com/p/B7hEe7-H_Uq/
87 Eye candy finished knobs https://www.instagram.com/p/B7hEvH1HB4v/
Nut height (Tote and knob)
controlled with washer
88 Showing problem with deep nut holes
https://www.instagram.com/p/B7r8x0tHnmZ/
89 Showing after adding washers
https://www.instagram.com/p/B7r8epCHIt3/
90 Showing washers that fit
https://www.instagram.com/p/B7r8XbxHuf2/
91 Showing you have to drill out the hole a little
https://www.instagram.com/p/B7r8Rbwn9Ft/
92 If hole too deep make a plug
https://www.instagram.com/p/CC-L8NsDWzN/
FINISHING THE WOOD
Blend repairs (if needed) with General Finishes Water Based Dyes. Med and Dark Brown.
220G w/ grain
Knobs I use the lathe and go up to 320 and maroon scotch-brite
¼ dowel and blue tape to hold parts while spraying
4 coats of Deft Clear Wood Finish Satin
0000 Steel wool sheds…. Sand between coat with
Hand rub final coat
FINAL TUNE AND TEST
When paint cured fit tote and knob
Final performance test
Other Topics
Repair of lazy lever cap
93 Showing removing original rivet https://www.instagram.com/p/B8Nca89g0hk/
Flatten and/or reverse the spring plate
94 Showing finishing repairhttps://www.instagram.com/p/B8NcLjGgYLz/
95 Showing final result https://www.instagram.com/p/B8Nb7xggyi6/
96 Showing adding glass to backs of stones for longer use ¼”thick glass cut to size. Silicon to back of dry stone https://www.instagram.com/p/CCC0qvqDrCX/
97 Showing making new posts for tote and knob https://www.instagram.com/p/B89css5jkOE/
98 Showing removing Y adjuster from frog https://www.instagram.com/p/CAVuF3pDB34/
For red Loctite, use heat to remove
99 Showing technique to reinforce area around front screw of Totes with a brass ring https://www.instagram.com/p/B9FoQXZj8DF/
Another repair is to cut slot out and insert wood
CAMBER
I generally use Chris Schwarz’s method to camber. From his book Handplane Essentials:
With a Honing Guide Make curved cutting edges using finger pressure.
A curved cutting edge is critical to most operations with your bench planes. The curve prevents the corners of the iron from digging into your work, and it allows you to correct the flatness of the face or edge of a board. But how do you create this curve, sometimes called a “camber” with a honing guide? There are lots of valid ways to create the curve. Here’s how I do it. I start with a #1,000-grit water stone. This stone cuts quickly enough to shape an edge or remove small nicks. Clamp your cutter in your honing guide and then (mentally) divide its edge into five “positions” (see the photo above). The trick to creating a curve is to put finger pressure at each position. At position “1,” put your fingers firmly against the corner and sharpen the corner for 10 strokes. Then move your fingers to the other corner (position “2”) and go for another 10 strokes. Then, at positions “3” and “4,” go for seven strokes. Then do a few strokes in the center at position “5.” Now check your work with a square. You need to learn what the curve should look like for each of your planes. Here are the basic principles: If the iron is bedded at a high angle greater than 45°, you need less curve. If the iron is bedded at a lower angle such as 12° or 20°, you need more curvature to get the same effect. And what is the desired effect? You want to take the widest shaving possible without the corners of the cutter digging in. There is math here. Having a .005″ arc-to-chord curve at 45° results in a curve of .0035″ being exposed out of the mouth. (If you have a bevel-up plane bedded at 12°, the same .005″ arc-to-chord curve will result in .001″ curve being exposed in the mouth – thanks to woodworker Rob Porcaro for the formulas.) The truth is you need to learn what the right curve looks like when you show the cutting edge to a straightedge. If there is too much curve, sharpen some more in the middle (position 5) to flatten the curve. If the curve is too flat, add more finger pressure or strokes at the corners. When you have a satisfactory curve, advance to the polishing grits (#4,000 and then #8,000) and repeat the same regimen. The polishing grits will remove less metal, but you definitely can increase or decrease the curvature while polishing. It takes a little practice to find the right curvature for your plane, but the rewards are enormous: Shimmering surfaces with a sensuous, scalloped and touchable texture. It’s worth the effort.
PUT FINGER PRESSURE AT EACH station and count your strokes.
Be sure to watch the sharpening stone –
it will tell you where metal is being removed.