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  Building a full size #4 Dovetailed Infill Plane by Don Wilwol 1 of 6  


Making an infill plane has been on my list for quite some time now. Making tools to me is more of a hobby than the actual woodworking.

 

If you are looking to build an infill, youíre welcome to follow me along. Iíll try to keep the blog up to date as time allows and would love feedback from others taking the same path.

The metal work of the infill intimidated me a bit and Iím not really sure why. I can weld, Iíve done my share of body work, gunsmithing and tin work, but the finish type metal work seems beyond my capabilities, which is why my first few I made from existing plane bodies.

But Iíve come to the realization that fitting the infill into an existing body is a lot of extra work you donít have when you make your own body. And the metal workÖ well it doesnít need to be that intimidating.

Iíll work through some of my issues, some of my mistakes, and some of the processes Iíve dug up. I spent a lot of time researching and looking at infill planes.
So first, if youíre thinking of following along, letís talk tools.

Iím still basically (for the hobby part of my life) a woodworker. Almost all of my tools are woodworking tools with a few exceptions. So let talk about the exceptions.

I have a horizontal metal bandsaw. Iíve had it forever and just discovered I can also use it vertically. In my defense, until now Iíve never had a need to use it vertically, so thereís my excuse for that bit of foolishness.

Almost everything online tells you you can do the cutting with a hacksaw, and I guess theoretically itís true. Even some of the professionals who have how-to blogs say they cut the planes out with a hack saw. I say bull crap. I think they are telling us that so we donít find better ways to make our own. If I had to cut them all with a hack saw, Iíd be back using the existing blanks.

Files. Youíre going to need files. Because of all my other hobbyís, one of which is buying box lots of crap, Iíve got a pail full of files. Flat ones, round ones, triangles shaped ones, some that work well, some that should become tent stakes, but you get the idea. If youíre new, and donít have a pail full of files, plan to buy quit a few.
A good hack saw, sanding equipment, good epoxy, countersinks, drill bits, drill press, and metal marking tools.

Taps. Youíll need several sizes for the cap, depending on how you plan to attach it.
A way to polish. Shiny is good in the infill world. This can be done with sandpaper but for brass, youíll really need a wheel and compound.

You can use a sharpy to color the metal to scribe with, but layout dye is about $4 for a bottle. And if you smart enough to not dump half the bottle all over your bench (yes I did) it will last a very long time.

A metal scribe. Again, I paid $3 something with a McMaster-Carr order. Spend the few bucks. Itís easier to use a metal scribe on wood, than the other way around.
Pick your size. I recommend staring with a smoother or jack. Something mid-size. Donít go to small or too big to start.


 
Woodworker's Guide to Wood Collection only $79.99 at Shop Woodworking
1 of 6  

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Ice Saw



   

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