I didn't have a lot of time to spend with the #45 this weekend but I did carve out a couple of hours to make a new tote and handle The original handle broke on me when I tried to drill out the pins that held it on. It was dry and cracked anyway so I would probably have replaced it regardless. And I just didn't like the original knob at all. It's just a ball:
I did the tote first. There is a web in the cast body that the tote has to hug and flanges at top and bottom for it to seat against.
I took a piece of Bolivian Rosewood and cut it to roughly the size I would need for the tote. Then using the old handle as a pattern, traced the rough outline and determined the location of the cut to hit the back of the cast web. I used the table saw and cut a kerf then roughed the shape out with the bandsaw and belt sander and OSS to get a good fit to the cast body.
Then it was time for my favorite part of making totes and handles
I put my bluetooth ear buds in and put some bluegrass on, grabbed some rasps and files and sandpaper and sat down and started whittling at the tote until it felt good in my hand. I sanded up to 220 grit. That's about as smooth as I like for tool handles. No finish applied yet but here is the finished part:
The differences between my tote and the original are subtle but make a big difference in the ergonomics for my big meat hooks. The biggest difference is that mine is a continuous curved surface. The original had pronounced flats on the sides:
I also shortened the horn a bit and necked the transition down to make a more comfortable spot for the crux of my palm and thumb to hook in. The original handle was serviceable but nothing more for me. This new one is a pleasure to hold though Replacing old totes and knobs on planes is something that I don't do unless it is necessary for some reason but that might change. Every time I do it, I find out just how much better a custom fitted tote can feel in use.
Next up was the knob which resides on the fence on my iteration of the 45 Combo Plane. I could have salvaged the original but I wanted to make one from the same piece of Rosewood as the tote so they would match. And I just didn't like the shape of the round ball of the original either. So I cut a blank and put it on the lathe and started shaping. I tried to keep it roughly the same overall height and diameter as the original but gave it a little more pleasing (at least to my eye) shape. Sanded up to 320 on the lathe. No finish applied yet but it was wiped down with Mineral Spirits before the pictures were taken. Sorry, no in-process shots on this one.
So there we have it! I'm really pleased with how this plane is turning out I also got the piece I was missing in the mail last week )
Big thanks to LJ CL810 for sending me his extra. Much appreciated Andy!
In the previous entry, I was debating whether or not to blue this plane. I have decided not. I really like the patina of the original steel so I'm gonna leave it and put a coat of wax or shellac on it to prevent rust. Thanks for all of the feedback on that! And thanks for checking in. Next I'll clean up some of the smaller bits and pieces and start putting this bad boy back together.
