The next "Build-along" project?

[steven c newman]

Well...got the latest hand plane all gussied up....
Stanley 45,t-4, top side view.JPG
Stanley No. 45, Type 3/4.....and it would be a shame to let it just sit out on a dusty shelf, somewhere....so, how about a box/case to stash it in? My Type 20 No. 45 already has it's own box, and there is no room to stash the Type 3/4 in there, too.. So, a trip to Lowes was in order...
Combo Plane Case, lumber supply.JPG
$17 of 1/2" x 6" x 24" Pine planks.....5 boards total. Have them clamped up in a bundle, while they get used to the weather down there in the shop. "Plan" is to leave the #45 assembled, and sit it down on it's skates in the box. Corners of the box will be hand-cut box/finger joints. Trying to decide on a choice of a lid......slider? Normal lift up lid? Or, just a 1/2" thick slab that closes onto the top of the box.....

The type 20 ( Roxton Pond, QUE. Canada ) oem box was done with the dust seal lid. May try that, and see about some Stanley labels......

Stay tuned...

[steven c newman]

Got the bench cleaned off enough..
Combo Plane Case, cleaned bench top.JPG
That I could lay out some tools..
Combo Plane Case, layout tools.JPG
Then figure out how long to make the box's sides....
Combo Plane Case, mitrebox.JPG
And cut a couple to length....
Combo Plane Case, 2 sides done.JPG
Used to be a single 24" long plank.
Combo Plane Case, not needed.JPG
Didn't even plug the tablesaw in....just a place to lay parts on....
Combo Plane Case, ends shot.JPG
One end was a hair longer than the other...Stanley No. 9-1/2 to shoot things even and square....
More layout work....involved the new Stanley Marking gauge, set to the thickness of the boards....then the chisel I will be using to chop with, set the spacing of the fingers..
Combo Plane Case, finger lay out.JPG
Narex 6mm Mortise chisel.
Carry the lines all around..
Combo Plane Case, finger layout tools.JPG
Stay tuned for Part 2....

[steven c newman]

Had to reset the handsaw a bit...
Combo Plane Case, depth stop set.JPG
Plate can be adjusted up or down, the bar can act as a depth stop..
Combo Plane Case, test cut.JPG
Test cut, to make sure I wasn't cutting too deep....hitting the baselines...
Combo Plane Case, baseline marked.JPG
Decided to just cut one set of fingers, at a time...needed to have a place to sit down, too..
Combo Plane Case, have a seat.JPG
Takes about 8 full strokes per cut...didn't take all that long to do...
Combo Plane Case, last cut.JPG
Waste is marked with an "X" for the next step..
Combo Plane Case, ready to chop.JPG
Got to about here, all set to chop....back decided it had had enough for one day ( 1 hour?) so I unloaded the clothes dryer, and hauled the hamper upstairs...done for today.

Let's see...new dogs?
Combo Plane Case, new dogs.JPG
from Kreg. That Marking gauge?
2 Stall Rust Hunt, marking gauge logo.JPG
With a Handlebar 'stache..for the brass wearplate.

Maybe tomorrow, I can get a little more done?
Stay tuned..

[steven c newman]

2 hours was about all I could handle today....chopped for a bit...
Combe Plane Case, half way chopped.JPG
Halfway, then flip over to complete the chops..
Combo Plane Case, corner #1 side 1.JPG
Use these fingers to lay out the matching set of fingers...
Combo Plane Case, corner #1, end #1 laid out.JPG
Bandsaw to make a few extra cuts...
Combo Plane Case, corner #1, sawn.JPG
Then the same routine of chops...1/2 way from one face, flip over, and finish the chops..
Combo Plane Case, dry fit #1.JPG
Then a dry fit. Long side has started to cup, a bit...

Repeat for corner #2...
Combo Plane Case, dry fit 2 corners.JPG
Add a spacer bar, for now....both to keep the case square, the other for the plane to reside on...
Combo Plane Case, spacer bar, dry fit.JPG

Back is hurting right between the shoulder blades, time to stop for the day....
Combo Plane Case, tight fit....JPG
Will be a nice, snug fit.....maybe tomorrow I can get corners #3 and #4 chopped? Then see about a floor panel?

Stay tuned

[steven c newman]

Back STARTED to feel a bit better....until some dummy decided to go back to the shop...
Combo Plane Case, 4 corners, handle end.JPG
And work on corners #3 and #4...
Combo Plane Case, 4 corners, side view.JPG
Checked this for square, outside is square..
Combo Plane Case, 4 corners, inside view.JPG
Inside is a bit snug....will mill a groove for the handle to slide down....and still not rattle...
Combo Plane Case, 4 corners,front corner.JPG
Have set up the Type 20 No. 45 as a 1/4" groove plane....box needs a bottom panel....

Stay tuned

[Matt Riegerix]

Neat project, you dont see finger joints not on the table saw to often.

[steven c newman]

Got bored last night...dangerous, I know......and put 2 planes to work..
Combo Plane Case, 2 planes.JPG
Nickel Plate was put to work, doing 1/4" x 1/4" grooves, to house the plywood panel for the bottom of the box...
Type 3 was put to work, ploughing a 1/2" wide dado. That way, it's handle can slide down the dado, for a better fit in the box..
Combo Plane Case, floor and slot.JPG
And completed a dry run with all the clamps..to make sure I had them all set up..
Combo Plane Case, clamp up dry run.JPG
Wound up needing cauls, as well...

This morning...had everything ready to go...
Combo Plane Case, pre glue up.JPG
Parts set out, clamps at the ready, supply of cauls ready.......except.....no glue IN the shop!
I also decided to clean up the dado...was looking a bit rough around the edges....Double checked the plywood bottom panel....1/8" too long? Buzzed that off..
New Bottle of Glue.JPG
trip to Wall E World..bottle of glue...a new cordless drill, 50 pound bag of FleaBag Food...and the Boss wanted a Saturday Newspaper ( ads)...got back home..
Combo Plane Case, glued up 1.JPG
Spread some glue, added the cauls and clamps....
Combo Plane Case, glue up 2.JPG
Will let this sit a day...while I work on building a lid...

Stay tuned..

[steven c newman]

Well..parts for a lid were cut up/glued up

Frame parts..
Combo Plane Case, lid frame.JPG
Corners to get finger joints....a panel for the lid's top..
Combo Plane Case, lid panel glued up.JPG

Let it sit a day....

So...Sunday Morning...clamps came off of the box...
Combo Plane Case, side cleaning.JPG
Between this jack plane, and a couple sanders.....the corners were cleaned up, sides smoothed out....needed the top edge planed level..
Combo Plane Case, level the top edge.JPG
So I could run a rebate all around...
Combo Plane Case, not the best way.JPG
Not the best way...chisel did help out at the corners...tested the fit of the combo plane IN the box...
Combo Plane Case, test fit the plane,again.JPG
Then cut and fit a "pad" for the plane to sit on level.

Set the box aside for a bit....have other items to do.....
Stay tuned for Part 2..

[steven c newman]

Lid panel blank came out of the clamps next......needed the glue joint cleaned up...
Combo Plane Case, what glue joint.JPG
Hmmm, what glue joint? Can you find it? Anyway, needed this trimmed for width and length...
Combo Plane Case, lid parts laid out.JPG
Something like this? Lid needed a rebate all around...
Combo Plane Case, first rebate.JPG
Long grain ones weren't too hateful....it was the cross grain ones that needed a "special" plane used,,,,
Combo Plane Case, better rebate plane.JPG
Wards (Stanley) No. 78...
Combo Plane Case, lid rebates done.JPG
All done? These rebates will fit into grooves in the frame of the lid...
Combo Plane Case, 1st lid groove.JPG
Like this...soon had all 4 done...
Combo Plane Case, lid grooves done.JPG
But...I still had one more set of rebates to mill...
Combo Plane Case, matching rebates.JPG
So the lid will sit down over the dust seal lip......once those were all milled. I laid out a start on the finger joints..

But, that was a far as I got....back was getting very sore, right between the shoulder blades....head was hurting, too.....decided that was just enough for one day....

Stay tuned

[steven c newman]

Tried out a way...to join the 4 sides of the lid's frame......so that no square holes will show.....like where the grooves, and rebates go through.....involves a few "different" cuts...first try was a tad sloppy, should be able to get better with each try....I hope..

Combo Plane Case, lid corner detail.JPG
1/2 pins, and a mitre.....3 more to do.....

[steven c newman]

Took my frustrations for the lack of a Postal Service today out on the pine parts...
Second corner was at least better that the first one...
Combo Plane Case, a good corner.JPG
Found I had to keep trimming the panel for width....both with the Stanley 45 and a jack plane..
Combo Plane Case, panel trimmer.JPG
lots of fancy cuts going on...
Combo Plane Case, fancy cuts.JPG
This is for the long sides...short ends had to then match up....
Combo Plane Case, lid dry fit problems.JPG
each dry fit got things closer....until..
Combo Plane Case, glued up lid, top.JPG
We had a glue up going on....a look at the underneath?
Combo Plane Case, underside of lid.JPG

Tomorrow, after I make sure the Post Office will not get their toes into the snow, I can remove these clamps, and clean things up....then see about what hinges and latches to install...
Combo Plane Case, awaiting the lid.JPG
So this plane can have some place to call a home....might even see about some labels?

Stay tuned..

[steven c newman]

Had a kid go out and shovel the sidewalk this morning, all the way up to the mail box....would have been nice IF he had also shoveled the driveway over to the alley....wound up getting stuck 5 times...before I could hit the city street. Will see how it goes tomorrow morning....Doctor's appointment.

mail did indeed arrive ( he also decided to WEAR his boots) so...
Combo Plane Case, LONG rods.JPG
One package had these two rods. The Stanley 45 these go to uses the screw-in versions....Package #2?
Combo Plane Case, main depth stop.JPG
Is a main depth stop. Those 2 holes are for attaching a shaped piece of scrap wood....shaped like a bevel....to help champfer an edge.


Ok, errands run....removed the clamps from the lid...
Combo Plane Case, lid, out of clamps.JPG
Meh....not the best looking thing..we have ways
Combo Plane Case, level the lid.JPG
Between this jack plane, and a couple sanders ( and a spot of glue where needed) was able to get things "presentable"
Combo Plane Case, hinge the lid.JPG
Issues with one set of hinges, led to this set being used...Clamps to keep things aligned, while the hinges were installed...then, flip the box and lid over..
Combo Plane Case, latch installed.JPG
And add the latch....then a block plane was put to work..
Combo Plane Case, round-over plane.JPG
All sharp corners were rounded over a bit....palmsander smoothed them out...

Then a coat of Gunstock Oil stain...
PIP Plane Case, lid opened.JPG

Will post a few more "PIPs" later....

Stay tuned...

[steven c newman]

Waiting on the stain to fully dry.
PIP Plane Case, front.JPG
Before a couple coats of clear gloss poly goes on..
PIP Plane Case, end view.JPG
And a few Stanley 45 labels....two will go on the end....then a "Stanley Tools" will go on the lid.

Will see about cobbling up a cutter holder....does not need to be labeled, though.

Almost done, stay tuned...

[steven c newman]

Working on the labels right now...

1st coat of varnish is almost dry enough to rub out...

Film @ 2300 hrs.

(Yes, I went ahead and stained the inside of the box...no varnish, though...)

[steven c newman]

Pictures? Pictures?


Ok, been a LONG time since I had to sit down and use a coloured pencil...and do a bit of "colouring"....
Stanley Label Work, filling in.JPG
Kept having to hit the sharpener...."Deep Emerald" wore down kind of fast....then try to trim the label out, without trimming a finger tip.....find some glue...
New Bottle of Glue.JPG
Schmear a bit onto the back of the labels....center the label onto the lid...
Stanley Label Work, centered.JPG
Use a pad to flatten things out, make sure it IS centered...
Stanley Label Work, glued down.JPG
Then cut and attach the 2 on the end...just one end is all Stanley bothered to do...
Stanley Label Work, end labels.JPG
So...waiting on the glue to dry....then brush on Varnish coat #2...and let that dry.....and then rub that down...

Stay tuned...