BLOCK PLANE Beautiful Tool by Al Huls

Handmade Turn a block of wood into a useful, BLOCK PLANE beautiful tool By Al Huls

his block plane project is a ent way. A simple template will great way to get started in help you align the parts during Tplane-making. A few inex- glue-up. Using the same tech- pensive items from Woodcraft niques shown here, you can create and some scrap wood are all you larger handmade planes to add need to make an attractive and to your hand tool arsenal. You’ll handy tool in just a few hours. It’s find a new satisfaction in your as easy as cutting apart a block and woodworking when you reach for gluing it back together in a differ- a wooden plane that you made.

Inexpensive materials. A block of thermally modified “roasted” maple provides you with strong, stable wood for your plane (see p. 68 for more details). Add a high- quality blade, two dowels and some scrap stock for the wedge, and you’re ready to build.

Solid performer. The plane shown here has sides made from walnut, but it’s also possible to build your version from a single block of wood, as shown on the pages ahead.

Photos: Larry Hamel-Lambert Feb/Mar 2017 | woodcraftmagazine.com 21 Keys to success: Accurate angles, a template, and good boring work

One nift y thing about this project is the transformation that occurs when you cut a solid block of wood apart, and then glue it back together in a diff erent way. It starts with accurate angle layout on a work- piece dimensioned with square corners. I make the angled cuts on a bandsaw, then sand the sawn surfaces smooth. But if you start with a longer block, the angled cuts can be made on a chop saw or tablesaw. Th e template is also important because it ensures proper spacing of parts. Give it a good coat of wax so that nose and tail pieces can be clamped to the template without sticking when you glue the parts together. Th e triangular piece can be glued in place separately, aft er the initial assembly is complete. Accuracy isn’t important with the dowels that pin the sides to the nose and tail pieces. But it is for the crosspin dowel that holds the wedge. Lay out the hole location carefully (see photo), and use backer blocks to prevent tearout when drilling through the sides. 1 Round the corners of your plane for appear- Find the angle and cut the block. Measure 2 ⁄4" from one end ance and comfort. Fine blade adjustments are of your block. From this mark, draw a 65° line toward the front made by using a mallet to tap the front end of the end, and a 45° line toward the back. Cut to these lines on the plane (to advance the blade) or rear (to retract). bandsaw and sand the 45° and 65° surfaces. Save the triangle 1 Lock blade position by tapping the wedge. cutout. Now, cut off the tip of the nose piece, creating a ⁄4" ﬂ a t . Tricky transformation: Cut the block apart, glue it back together, then add dowels and wedge

Note: Part dimensions are for 5 1 a plane blade 1 ⁄8" w × ⁄8" t 11 1 ⁄16" TRIANGLE TAIL PLANE SIDES 6"

3 ⁄16" NOSE 45°

65°

11 3 1 ⁄16" 3 ⁄4"

11 1 1 ⁄16" 2 ⁄4"

Step 1: Start with a blank that’s 2 × 2 × 6" or larger. Step 2: Set aside the side pieces, and cut the block into 1 Rip your block ⁄16" wider than the width of your plane blade. three angled pieces as shown. Sand surfaces smooth to prepare After ripping, it should be square in section. for the next step.

22 Assembly Template Place nose piece here.

Place tail piece here.

Find the hole location and drill. From the center of the plane 5 side, measure down inside the throat ⁄8" from the top edge. Place 1 a rule against the 45° ramp and measure out ⁄2". Use calipers as shown at left to transfer your mark to the outside of the plane wall. 1 Center a sharp ⁄2" brad-point bit on this mark, and drill through both sides of the plane, using backer stock to prevent tearout.

65° WEDGE 1 5 1 45° ⁄2 × 1 ⁄8 × 3 ⁄2" 1 Taper to ⁄8"

Plane blade (bevel down) Template (See photo above) CROSSPIN DOWEL 1 1 ⁄2" dia. × 2 ⁄4"

1 Cut ⁄4" ﬂ at here. DOWEL PIN 3 5 ⁄8" dia. × ⁄8" Mouth

Step 3: Glue parts back together. Alignment is Step 4: Install dowels and make the important, so use a plywood template (photo above) wedge. Glue the dowel pins, but not to make sure parts are properly positioned. the crosspin dowel.

Project photos: Rick Dubbs; Illustrations: Frank Rohrbach III Feb/Mar 2017 | woodcraftmagazine.com 23