Aside from its sheer size, the main difference between this plane and the jack plane is the tote. The try plane is fairly heavy, so it needed to have a closed tote. I did my best to make a pleasing shape. The back of the tote is basically the same shape as the open tote for the jack plane and the front came from totes I saw online. I also used photos of a plane I saw at a PAST tool show last year.
|Prototype tote in poplar all marked out|
The build process was very similar that of the jack plane, so I'll go over that quickly in pictures.
|Squared up the blank, cut off the 1/2" thick sides, smoothed and squared the sawn surfaces|
|Marked out the throat on the main body|
|Sawed out the throat and planed the sawn surfaces flat and square to its sides|
(prototype poplar tote shown)
|Knifing a line on the sides to mark the rear aspect of the abutment recess|
|Made a sketch and calculated where the front aspect of the abutment recess will go|
|Marked for the abutment recesses|
|Chiseled and routed the recesses|
|Made the slot in the main body bed for the cap iron screw|
|Glued up the plane body using cauls to distribute clamping pressure and to keep the sides and body in line|
|Removing glue squeeze-out and leveling the rear aspect of the abutment recess with the bed|
|Prepared a wedge complete with recess for the cap iron "nut" (shown)|
|It took a few iterations of planing and fitting, planing and fitting to get the right fit|
|Nice tight fit of iron and wedge to the recesses|
|Then marked out the blank for the final tote|
|Cut the shape with saws, shaped with chisels, rasps and files|
|Figured out where to place the tote - a little too close to the iron in this position|
|This gives better access to the iron, so I marked and then mortised for the tote|
|Got a good fit|
|Used hide glue to affix the tote|
|Needed to do quite a bit of work on the iron|
|Better, but still not flat - took a long time to flatten the back.|
I then put a slight camber on the iron and sharpened it.
|Added the same shaping details as on the jack's body.|
Took some test shavings and all was good.
|Sitting and drying|
|Here's how the plane fits my hand. I didn't lower the surface that the tote is|
mortised into like I did on the jack plane, but I can still reach the iron with my finger.