Veritas® Bench Plane Tote - Lee Valley Tools

1 2 3 4 5 6 798765432Cut blank to this lineGrain direction1Veritas® Bench Plane Tote1090 Morrison DriveOttawa, OntarioK2H 1C2 Canada© Lee Valley Tools Ltd. 2009814 Proctor AvenueOgdensburg, New York13669-2205 USAPrinted in Canada.PLN-042Sheet:Scale:Units:Rev. 41 of 11:1Inches

Tote Template for Veritas ® Bench PlanesInstructionsTote Template for Veritas ® Bench PlanesInstructionsThis template can be used to make a replacement handlefor the line of Veritas ® Bench Planes, including the #4Smooth Plane, the #4 1 /2 Smoothing Plane, the #5 1 /4WBench Plane, and the #6 Fore Plane.The shape shown is that used on the standard productionplanes. Providing the critical dimensions (i.e., handle rodhole and associated mortises) are maintained, the outershape can be modified to suit the user. The template hasa 1 /4" scale printed along both edges of the sheet. Theseshould be checked against an accurate rule to ensure thatthe template is at full scale before it is used. There aremany reasons that a printed template may be off scale,including printer accuracy and humidity (like wood,paper moves with moisture content). In most cases, scalethe output from the printer, or use a scaling photocopierto make any necessary adjustments. Also, do not printthe template until you are ready to use it.Bore out the handle rod hole. Long narrow holes cansometimes be a problem to keep aligned. It may beeasier to bore halfway through from either end of theblank, providing the blank is perfectly parallel andcarefully aligned in the drill press.Drill tote rod hole centeredon and completelythrough blank.Start by cutting a blank to slightly larger than thedimensions shown on the template (4 9 /16" × 4 1 /16"). Notethe correct grain direction. The thickness shown is thatof a stock handle, but feel free to make any adjustmentsto suit your grip.Cut out the template along the outer box lines and pasteit to the handle blank. Spray adhesive is suitable forthis. Avoid using white or carpenter’s glues, as theirmoisture content will deform the template.Trim the blank to match the outer template.Transfer the handle rod hole axis onto the top andbottom edges of the blank and mark the center point.Lay out the top and bottom mortises and remove therequired material.Note: Depending on the method you use for forming themortises, it may be easier to do this step before boringthe handle rod hole.Mill out upper and lowercavities as needed.Glue template tohandle blank.Transfer axis lines ontotop and bottom surfaces.

Tote Template for Veritas ® Bench PlanesInstructionsBore out the two holes that form the tightly curved partsof the handle contour.Drill out indicated holesto establish tightradii curves.Saw outhandle shape.Trim the workpiece to the top and bottom contours ofthe handle.Trim the workpiece to the front and back contours.Trim the front contour first and then do a trial fit on theplane. Any errors are easier to correct while the blankstill has flat reference surfaces. Also, if the error is notcorrectable, the minimum amount of work has beenwasted.Final shaping can be done with a combination ofround-over router bits, rasps, carving tools, sandpaper,etc. Proceed carefully, testing the grip often to ensurea comfortable handle. Sand the final shape smooth andfinish as desired.Shape to suit.Depending on the final shaping method, it may beworthwhile to cut the contours slightly oversize.742© Lee Valley Ltd. 20091090 Morrison DriveOttawa, OntarioK2H 1C2 Canada1-800-267-8761www.leevalley.com814 Proctor AvenueOgdensburg, New York13669-2205 USA1-800-267-8735customerservice@leevalley.comINS-402 Rev. APrinted in Canada.