I didn’t think to take pictures of the first step. So what isn’t seen in the following pictures is that the plane is placed on the surface plate and both sides are checked for parallelism with an indicator mounted on a surface gage. It makes a difference when it is clamped to an angle plate. If it is out, the difference is split so that the least amount of metal needs to be removed. In machining usually the largest surface is machined first. In this case that surface is already machined so the body is clamped onto the angle plate. See pictures 1 and 2, anything longer than a #4 needs to be clamped to two angle plates. The two angle plate process is not shone. You will however see two vises being used to grind the bottom on a longer plane
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| The other side is then ground parallel to the first. See picture #3. |
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There is nothing holding the plane except for magnetic force. Now think about this, even if the bottom isn’t flat but has a twist it is removed during this stage. It is called clamping in the free state.
I have been asked many times if I can do the bottom and not the sides. Some want it this way because it would be cheaper. Others want to preserve the original look of the plane. The answer is yes I can. I will grind it anyway you want because you are the paying customer. But I grind the sides to help control twist. Also so the precision vise or vises can clamp better. They have no floating jaw. Since the side was ground off the bottom, and then the other side, the bottom is more square when clamped in the vise. I do not guarantee flatness if I do not grind the sides. The charge to do it ether way is the same. If I don’t grind the sides I make more money per time invested. I grind the sides because it looks nicer, helps control twist and it helps in clamping so less material is removed from the bottom. Also some really like the sides being ground square because they like it square so it can be used on a shooting board.
The body is then clamped in a precision vise. Do to the nature of the vise, good sides on the plane help the clamping process without allowing twist to inter back in. Next the bottom is indicated in so that the lowest points at each end are parallel to the bottom of the vise. The high spot is also found. See picture #4.
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| And the bottom is then ground. Pictures 5 and 6 shows the bottom being ground on a #5. |
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Anything longer than a #4 needs to be held in 2 vises. The wheel is touched off on the high spot and then lowered .001 and the entire bottom is covered by the wheel. Then the process is repeated until the bottom is cleaned up. On the longer planes it is not uncommon to stop grinding and redress the wheel. Then pick back up and continue grinding. Once the bottom is cleaned up the wheel is redressed. When grinding a long piece of metal it heats up in the middle. The plane is then picked up again and the wheel is lowered .0005 at a time. You can hear the ends cutting but nothing in the middle because it is low. When the bottom is cleaned up again a spark out pass is taken to insure flatness. I like to finish with a .0002 dept of cut just to make the bottom uniform in finish.
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| Picture 7 shows a #4 on the grinder finished. |
Next pictures #8 and #9 show the final inspection. The final inspection is however done with it still clamped in the vise or vises. I state the final inspection number and although I have done everything I can to make it a true reading. There is always a possibility that my numbers could be off up to .0005. when it is released from the clamp
I would like to note that in no picture did you see the frog or any of it clamped together in assembly. When the blade is clamped, the clamping force is directed into the frog, not the body. The frog is held to the body by two screws. Remember the largest surface would be machined first then the seats would be cut. Also the frog would be finished and then assembled. It would not be re-machined in assembly. That would be counter- productive.
See wives tails for more information.
My prices for grinding planes are $40 for a # 3 and # 4. Then I charge $10 per size thereafter, so a # 8 is $80 plus you pay shipping both ways. I do not charge extra for 1/4 or 1/2 sizes. I give a $5 discount per plane if more than one is done at the same time. Precision grinding takes time. A #4 takes about 3 hours to do.
I want only the body and the plane iron to be sent to me. It is to easy to lose parts or to get them mixed up. I ask that the plane iron be to be sent because sometimes I can clean it up and help so that the back doesn’t need to be lapped as much. See picture 10. I have found that most people want to do their own sharpening. So I do not do any sharpening. So there are no pictures of shavings. Using it also burnishes the bottoms and I think the owner should do that.
If you want a more traditional look after grinding sand it down using a gray scotch brite. Then wax it using the scotch brite as a waxing pad.
NOTE: If you buy a plane from me I give a 10 day money back guarantee and I will pay return shipping. In ten days you will know if you are going to keep it. The guarantee does not cover a problem like a crack in the handle if it was called out in the advertisement as having a crack in the handle.
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