Shop Made A13 Infill - with Ron Brese's help

[Brian Kent]

About a year and a half ago, on my quest to have a really fine smoother, I read everything I could about about making infills from scratch.

The design I like the best is the A13.

On Sawmill Creek I started asking questions about thickness of brass and professional infill plane-maker Ron Brese started e-mailing me with great information.

To make a long story short, Ron guided me as I made a Brese-style Brass and Cocobolo A13 Infill. I bought the blade from Ron, and then surprised he me with the cap also and thumb screw also.

I won't pass along Ron's methods, but I will say just 5 words if you promise to keep them under your hat: "Drywall Nails and Elmer's Glue"

I finished this in Autumn of 2008 and have never posted the finished product because I wanted to wait until it worked right. Very recently I upgraded my knowledge of sharpening and the products I use and the break-through happened. Full width .001" shavings with a flat, shiny surface left behind on very hard wood (Padauk). So here are some photos, not of the plane when I shined up all of the brass, but the day I learned to sharpen it right and made it work.

I thought it had worked OK until I visited Ron in Georgia last May and used his well-tuned plane. It showed me what to aim for.

[Leigh Betsch]

Way cool.

I've been making a few planes also, but none to this level of perfection. It gives me some inspiration. I've been reserving the smoother build for an infill plane project rather than a woodie. The problem is I'm selling my CNC mill in about a week and I am not ready to start (and finish) the infill metal yet!

I'm guessing you didn't use a CNC mill for the metal work, did you hand form the shapes?

[jerry nazard]

Brian,

Stunning plane! Would you share a bit about your sharpening epiphany?

-Jerry

[Jeff Wittrock]

That is a beautiful plane Brian! I have made a couple of woodies, but have not had the courage to try an infill. Congratulations.

-Jeff

[Brian Kent]

Thank you Leigh.
I cut close to a line with a jig saw. The final shaping was on a router with a carbide pattern bit, matching the shape of a plywood pattern.

Jerry,
When I went to the Lie-Nielsen traveling workshop, I saw somebody using waterstones. I got some Shapton stones, but he was doing his work on a Norton 1000 / 8000 combo stone.

What was different was that using stones instead of scary sharp, the sharpening happened many times faster. I did not have nearly as many strokes to introduce rounding on the back of the blade. I also did not realize how rough my edges were, even through the surfaces looked polished. I had very highly polished ragged edges.

I know the problem was my technique, and not the scary sharp sandpaper system, but this is working far better for me. With a much sharper edge, the whole plane is smoother, the motion more even, and the final result flat and glassy.

[David Christopher]

Brian, you have a beautiful plane and it is somthing to be proud of.
from the looks of the pics, it works as good as it looks

[Doug Shepard]

Great lookin and performing plane but ya gotta give us more on this


....
I won't pass along Ron's methods, but I will say just 5 words if you promise to keep them under your hat: "Drywall Nails and Elmer's Glue"
....


Inquiring minds want to know.

[David Gendron]

That is a great looking/working tool you made there!
On an other note, are working on a rocking chaire? Maloof maybe?

[Bruce Page]

Beautiful!

[Brian Kent]

Yes, I am, David, and having an awesome time.

Doug, you would have to contact Ron on this, since I can't distinguish between his proprietary knowledge and what everyone knows.

I confess. No Drywall Nails and Elmer's Glue.

Here are some construction photos once the shell is assembled:

[Brian Kent]

And some more.

[Scott MacLEOD2]

How did you affix the sides to the sole. Hoping its not drywall screws or elmers glue.

Thanks, Scott

[Brian Kent]

That's the part I told Ron I would not share. Sorry.

[James Taglienti]

That thing looks like it is taking a pretty nice shaving, how much better could Mr. Brese's plane really be!?

[Paul Murphy]

Brian, that is an impressive piece of craftsmanship! I'm sure you will be rewarded with wonderful surfaces on every project you use it on.

[Brian Kent]

James, that photo is the first time it worked like Ron's plane. Up until this week I could never get that.

[Leigh Betsch]

Can you divulge the thickness of the brass sides and sole? Is the sole brass? At cost of brass these days I may have to substitute silver or gold.

[Brian Kent]

Sure, Leigh.

The sole is 3/8". The sides are 3/16" stock. The cap is 1/2" thick. All Brass alloy 360.

I bought this locally at KH metals. I think they also ship (www.khmetals.com). The total brass stock cost $81, which was a lot better than I had found elsewhere.

The cocobolo was hard to find in thick pieces, so I used 8/4. Walnut would be much easier to find in 10/4. The back part is made in 3 pieces, handle and 2 little side panels. The tote was made with 2 thicknesses of 8/4, glued top and bottom.

[Eiji Fuller]

gorgeous! Really nice job. How much time do you have in it?

[Bryce Adams]

Brian,

I have a Brese small smoother kit that I'll get started on soon, and I need to decide how to finish the infill. What type of finish did you use on your infill?

[Dave Anderson NH]

Very nicely done Brian. I built a Spiers #7 infill smoother a few years ago and it was a lot of fun.

[Brian Kent]

gorgeous! Really nice job. How much time do you have in it?

I didn't keep track, but every time I do something that I totally didn't understand when I started, it takes about 40 hours. So that's my story and I'll stick to it.

[Brian Kent]

Brian,

I have a Brese small smoother kit that I'll get started on soon, and I need to decide how to finish the infill. What type of finish did you use on your infill?

This part was really fun. First time around, I rasped, then failed, then sanded through the steps to 320 or 400, then used the Beall's Buffing System which ends with Carnuba wax.

The second time, I had discovered Micro-Mesh Cushioned Abrasives:
http://www.rockler.com/product.cfm?page=11435&filter=micro%20abrasives

I took the wax off with mineral spirits, then started through the Micro-abrasives: 1500, 1800, 2400, 3200, 3500, 4000, 6000, 8000 and 12000 grit. It took a couple of hours while watching TV. As it is now there is no finish at all besides the sanding.

It feels like glass and cocobolo got together and had babies.

[Brian Kent]

Very nicely done Brian. I built a Spiers #7 infill smoother a few years ago and it was a lot of fun.

Dave, do you have a picture of that, here or on your website? I would love to see that.

[Dave Anderson NH]

Brian, I don't think I have it on the website, but it was posted here on the creek a few years ago.