Building a wooden hand plane for smoothing wood surfaces can be a rewarding and satisfying project for any woodworking enthusiast. It not only allows you to create a tool that will improve your craft, but it also teaches you valuable techniques that can be applied to other woodworking projects. Here’s a step-by-step guide to building a simple yet effective wooden hand plane.
Materials Needed:
- A piece of hardwood (e.g., maple, beech, or oak) for the body of the plane.
- Plane iron (blade) or a steel blade.
- Wooden wedge for securing the blade.
- Sandpaper or a smoothing block for finishing.
- Wood glue or screws (optional depending on design).
- Chisels and a saw.
- A hand plane or a router for shaping.
- Rasp or file.
- Wood finish (e.g., linseed oil or varnish).
Step 1: Select Your Wood
The first step is choosing the right wood for the body of the plane. A dense hardwood is necessary for a stable, durable tool. Maple, oak, and beech are all excellent choices, as they have the strength to withstand the pressures applied during planing.
Select a piece of wood that is long enough for the body (typically around 12-14 inches), with a flat and straight grain. The wood should be free of defects such as knots, as they can weaken the structure of your plane.
Step 2: Mark and Cut the Basic Shape
Start by marking out the dimensions of the plane body on the selected wood. The body typically has three main components:
- The sole: This is the flat surface that rests on the wood you are smoothing.
- The sides: These are the edges that guide the plane.
- The mouth: This is the opening through which the blade protrudes.
Use a square and ruler to mark straight lines and angles. Then, use a saw to cut along the edges, making sure the cuts are as precise as possible. The body of the plane should be around 2-3 inches wide, with a thickness of about 1-2 inches, depending on your preference.
Step 3: Create the Mouth
The mouth is the opening through which the blade extends. You need to carefully cut out this section of the plane. The mouth should be roughly centered along the length of the plane body, with enough room for the blade to protrude slightly. A chisel and mallet can be used to carve out the mouth, or you could use a small saw followed by a rasp to shape it.
Ensure that the edges around the mouth are smooth and clean to prevent the blade from catching during use.
Step 4: Shape the Bed and Blade Placement
The bed is the surface inside the plane where the blade will sit. It should be set at a slight angle (around 45 degrees) to allow the blade to effectively shave wood. Use a hand plane or a router to carve the bed, making sure that it is smooth and even across the entire surface.
Once the bed is shaped, mark the position where the blade will sit. The blade should be positioned so that it is slightly tilted and extends through the mouth, allowing you to adjust its exposure as needed.
Step 5: Make the Blade and Wedge
The blade, or plane iron, is the heart of the plane, and its shape is crucial for effective planing. You can purchase a pre-made blade or repurpose an old chisel. The blade should be slightly longer than the width of the plane body and should be ground to a bevel for cutting.
The wedge is used to secure the blade in place, preventing it from shifting during use. The wedge should be shaped so that it fits snugly into the mouth of the plane, pressing the blade firmly against the bed. A simple triangular or trapezoidal wedge shape is commonly used.
Step 6: Assemble the Plane
Once the blade and wedge are ready, it’s time to assemble the plane. Insert the blade into the bed, and position the wedge behind it. The wedge should be driven into place, forcing the blade to sit firmly against the bed. If the wedge fits well, the blade should be secured tightly.
Before securing the blade permanently, test the fit and adjust the exposure of the blade by tapping the wedge slightly to raise or lower the blade. The blade should extend just enough to shave thin slices of wood from the surface.
Step 7: Fine-Tune the Blade and Plane
After assembly, the next step is to fine-tune the blade for smooth performance. Use a sharpening stone to hone the blade’s edge to a fine, sharp bevel. A sharp blade is essential for a smooth, clean finish when planing wood.
You can also smooth and round the corners of the plane body using sandpaper or a smoothing block to ensure that the plane will glide smoothly over the wood.
Step 8: Test the Plane
Before you start using the plane on your projects, test it out on a scrap piece of wood. This will allow you to check the blade’s alignment, the smoothness of the body, and the effectiveness of the mouth. Adjust the blade depth as needed by tapping the wedge or making slight adjustments to the bed.
Once the plane is working well on scrap wood, it’s ready for use on your main project. Regular maintenance of the blade (sharpening as needed) will ensure that your plane continues to perform well.
Conclusion
Building a wooden hand plane is a fantastic project for those interested in woodworking. It requires precision, patience, and attention to detail, but the result is a valuable tool that will improve your ability to smooth wood surfaces. Whether you’re working on a fine furniture project or restoring old wood, a custom-made hand plane will help you achieve smooth, even results.
For further improvement in your woodworking skills and to discover more tools, consider exploring Ted’s Woodworking Course here.