Last weekend, Adam bought a block plane kit form Hock Tools, at the Woodworking in America market place. We finally had the time, this weekend, to put it together.
I tried to let Adam do as much of the work as possible, but I had to help a little. He started by assembling the rear and drilling locating holes. Next he cut the supplied dowel to make the locating pins.
After pinning the rear in place, he repeated the process with the front.
Then he marked the location of the opening in the middle. Once everything was located and marked, the instructions say to take it all apart and apply paste wax to the bottom and the inside surfaces to prevent glue squeeze-out from sticking. We ran into a slight problem getting everything apart at this point. We drove the pins all the way in and they seated very tightly. The thing did not want to come apart… A pair of pliers and a judicious use of a chisel on the outside ends remedied the situation, but I would advise not seating the pins all the way down next time.
Adam applied the paste wax, with a paper towel, then the glue, with a brush.
We then re-pinned it and clamped it up and let it set overnight.
Day two started with sharpening the blade that came in the kit. I flattened the back on my Work Sharp sharpener, then sharpened the front to a 30 degree bevel.
After honing it on the leather wheel, the blade was razor-sharp.
With the blade ready and set in place, we sanded and planed the wedge until we had a nice fit.
Then Adam flattened the sole of the plane on a sheet of sandpaper. He used a small mill file to open the mouth just enough for the blade to slip by.
With all of that done, it was time to shape the plane. We sliced off all of our dowel pins and sanded the sides flat. This enabled Adam to cut the desired curves to the front and back, on the band saw.
The curves were smoothed out on the spindle sander.
Then the fine tuning of the shape began. Adam used my Auriou rasps to round off all of the outside edges.
After a final sanding, we set the blade and he gave it a test run.
Perfect shavings! Adam’s plane is complete and just the right size for his small hands.
Thanks again to Ron Hock of Hock Tools for putting together this neat little kit, just Adam’s size.