Someone asked me to describe the process of making my router planes...

**The Spin Doctor** · 4th April 2023, 09:21 PM

I was selling the stanley spear point blades a while back and was asked to describe the process of making the router which is the fifth pic...

It's a multistep process that utilises two templates.

The second two pics are of the template used to shape the outer profile of the body and the mouth. The handles are so I don't have a catastrophic failure that nibbles my fingers... Personally, I like my fingers, I'm kinda attached to them so take precautions... It's pretty straightforward, in that it's a normal pattern bit with a bearing at the bottom of the straight cutter that's mounted in a router table.

The third pic is for a template that allows me to remove material to stylise the router body more. See pic four or the raised sections and where material has been removed. The router bit in this case is pattern bit with a bearing at the top of the cutter.

For the raised sections where the knobs will be mounted, the body needs to be mounted on a lathe and those sections turned. I had a face plate set up to attach the base to.

Once it's roughed out, there is a still a fair bit of shaping needed to round the corner and file the right angles that are needed. The brass parts are a whole other job, but they don't require a milling machine. But a drill press or lathe is needed.

I went looking for these old templates and was quite happily surprised to find I had a coco bolo base ready to go. I also found enough coco bolo to make two more knobs so now I just need to source some brass to make the rest of the parts. Sadly, in this country the brass will probably cost over $100 so it might have to wait till I go overseas. I don't want to buy 2 feet of 1/2" brass plate just to use 3".

The knobs are turned separately.

Now, these were all done before CNC was a thing. If you have a decent CNC machine with interchangeable heads, you can do all this on one of them. It's a pretty simple pattern with basic profiles that any overhead router could deal with.

I'm much better in an analogue situation where I talk, rather than digital where I type it all out. So, if it's not clear don't hesitate to ask questions.

**The Spin Doctor** · 4th April 2023, 10:26 PM

I haven't produced any of these in 20 years or so.

The more I look at the templates and the last base it looks like I had a round over bit of sorts that had a top mounted bearing. When you look at the template a track is clear so there was a router bit cutting into the template...

Where I got that bit... No idea anymore. Probably Lee Valley.

**D.W.** · 5th April 2023, 12:07 AM

The final aesthetic is superb!

**IanW** · 5th April 2023, 08:47 PM

? Where do you buy your brass, SD? Just eyebalilng the amount you seem to have used I would have thought it would be something south of $20 worth. Not that that helps, GWS where I buy my brass now have a minimum order of $50. Unfortunately, I never have any trouble exceeding that, even with a "small" order..

Actually, brass has gone up at a rate well above inflation these last few years. I had to revise my material cost estimates for my shoulder planes to almost double what they were 4-5 years ago!

When you get around to finishing the cocobolo plane, please do a WIP for us if you can....
Cheers,

**Simplicity** · 5th April 2023, 09:52 PM

There gorgeous,you could sit them on your desk, an never get them dusty.

Unfortunately all metal prices in Oz have gone North considerably.[emoji3064]

Cheers Matt.

**Chief Tiff** · 5th April 2023, 10:07 PM

Thank you; that’s a fascinating process. How many routers do you think you made with these?

**Cklett** · 5th April 2023, 10:13 PM

That's a great looking design. Love it.

Sent from my SM-G781B using Tapatalk

**The Spin Doctor** · 7th April 2023, 12:56 PM

Originally Posted by IanW

? Where do you buy your brass, SD? Just eyebalilng the amount you seem to have used I would have thought it would be something south of $20 worth. Not that that helps, GWS where I buy my brass now have a minimum order of $50. Unfortunately, I never have any trouble exceeding that, even with a "small" order..

Actually, brass has gone up at a rate well above inflation these last few years. I had to revise my material cost estimates for my shoulder planes to almost double what they were 4-5 years ago!

When you get around to finishing the cocobolo plane, please do a WIP for us if you can....
Cheers,

I was in Canada at that time so went to Metal Supermarket. They sold in any length the buyer wanted... Here, last time I tried looking, they want you to buy in large lengths so wasn't financially practical. Will GWS cut to your size or do they demand a minimum length?

The brass used: 1/2"x1 1/2"; 1" and 3/4" round bar; 3/4" hex bar; and 8 1/8" x 4" x 1/8" plate.

Tell me about price rise. Last time I visited Canada I went and bought some copper round bar. 1' lengths at 1/2" 3/4" and 1" Total was less than $100. Now, I have family coming in two weeks and checked on the price to see if bro could bring some... 1" at 1' was at $125. Didn't even bother checking the other prices.

**The Spin Doctor** · 7th April 2023, 01:17 PM

Originally Posted by Chief Tiff

Thank you; that’s a fascinating process. How many routers do you think you made with these?

12 if my brain cells are correct.

I missed a real opportunity when I first started out making these. I had posted them to some site that allows those that have made planes and such post there work... I was contacted by a guy that reproduces the really rare ladybug planes. He asked if I wanted to trade. I get the impression he was just starting out to in making them. I knocked him back. What a dumb move on my part. I think he's gone now.

**The Spin Doctor** · 7th April 2023, 02:16 PM

Originally Posted by Simplicity

There gorgeous,you could sit them on your desk, an never get them dusty.

Unfortunately all metal prices in Oz have gone North considerably.[emoji3064]

Cheers Matt.

Funny thing about the first one I ever made. I'd only ever seen a 71 in pictures so knew nothing about dimensions and such so it's quite small by comparison. I took it with me to a woodworking club I belonged to show. One of the fellas said: Nice salt and pepper shakers. He really meant it LOL. I thought I need to find a real one and revise the style a bit.

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