When Jill and I decided that we would take the plunge and pursue this road less traveled - I was worried that full time planemaking would get boring and heaven forbid... monotonous. In the beginning, the excitement and challenge of building infill planes was incredible - the thrill of actually being able to do it was more than enough. Some of that “thrill of learning” has dissipated over the years, but I am happy to report that I still love making them. And these last two A5’s perfectly illustrate why.




The first plane is stuffed with English Boxwood. This is the second Boxwood filled plane I have made - the first was an XSNo.4. As far as I am concerned - English (or Turkish) Boxwood deserves to be placed alongside Brazilian Rosewood as far as workability and joy to use. I have a deeper appreciation as to why it is so prized by turners. Working with the Boxwood was such a fun departure from all the dark woods - I felt like I was building a brand new model.



The sole and sides are 01 tool steel, the blade is 2-1/4" wide high carbon steel and the bed angle is 50 degrees.



The second plane is also special because it has specs that I have not combined before. It is a really small A5 compared to all the others I have made. It is also extremely comfortable in the hand. The infill is Brazilian Rosewood, the sides and sole are 01 tool steel.




What was “new” is the 47.5 degree bed angle coupled with a 7-1/2" long sole. Until this plane, all the 47.5 degree bedded smoother had a 7-7/8" sole. I have made a lot of A5's with 7-1/2" long soles - but they have all had a york pitch. The york pitch raised the blade just enough to allow for the handle to be pushed in closer to the lever cap. This in turn allows the sole to be shortened. This may seem a bit over the top -but when you are trying to fit a handle to a persons hand size - every 1/16" matters!

Over the last several months, quite a few people have noticed and asked about the “green mallet” in the background of many of my photos. Here is the story...

I have never used or owned a proper mallet and when my friend Andrew Dix heard this - his wheels quietly started spinning. A few months later a package arrived.



Everything about this simple looking tool made sense to me and more importantly - every detail had been carefully planned out... nothing was accidental. The shape of the head was elegant, but also performs its function perfectly. The slight taper put a bit more weight at the top - where maximum force can be applied while striking. The handle is shaped in a way that your hand holds the mallet in a balanced position.




But the above photo is what really did it for me. This tells me the person who made this tool is aware of function first, but the aesthetic is just as important. Andrew took the time to rotate the endgrain of the handle so it lined up with the endgrain of the Verrawood head. And the Padauk wedge bisects it perfectly. This may seem like an insignificant detail - but this is the sign of a toolmaker who is passionate, thoughtful and knows when to add a “touch”.

I have been using this mallet daily ever since it arrived, and I have not a single complaint or comment to improve on it. There is a lovely dark band around the head where it has struck the ends of many of my Imai chisels. Aside from the discoloration - there is no damage. I suspect Riley and Lucas will be using a pristine mallet when I am long gone.

Very shortly after this mallet arrived, I contacted Andrew to (strongly) suggest that he consider making these available to the public. He was at first a little surprised and reluctant - but every time someone sent me a note to ask about the mallet, I contacted Andrew to let him know of the interest. I am thrilled that he has gathered appropriate materials and is now prepared to take on a few commissions.

The base mallet has a Verrawood head and either Cocobolo or East Indian Rosewood handle (any wedge material) . The price for this mallet is $250 US. He also has a good supply of African Blackwood, Kingwood, Ebony, Palisander Rosewood, Brazilian Tulipwood, Bois de Rose and Zircote as alternative handle material. The mallets can range from 16oz. to 24oz.

Andrew Dix can be reached by phone (804)678-9246 or email; dixja@vcu.edu

If anyone is interested - an offcut from your plane would make a wonderful wedge in one of Andrews mallets.

Over the last 8 days, I have fit the front buns and rear infills of 7 coffin smoothers. Two XSNo.4ss's, three No.4ss's and two A5ss's. Six of these planes have Ebony infills. Needless to say - my hands are disturbingly filthy. The fitting process goes something like this;

1). Waste out the bulk of the infill using saws (thanks again Mike!).



The above shoulder cut that defines the overstuffing still feels “dangerous” - even after 100+ times.

2). With the bulk removed - I turn to files, rasps and chisels to further refine the shape.

3). Once the footprint is close - I add in my 1/2" wide, by 3-3/4" long shoulder rebate plane to get the fit of the shoulder to mate perfectly with the sidewall. There is still some refining of the footprint involved - but at this stage it is a bit of a dance between fitting the footprint and the height of the shoulders of the overstuffing.



The above photo is one of many tests of the fit between the overstuffing and the sidewalls. The thing that makes coffin shaped planes a bit tricky is there is very little wiggle room with regards to the fit. On a parallel sided plane, the infill can be slid in from either end. With a coffin plane on the other hand - it needs to drop down from the top.

Take an A5. The handle is already shaped, the bed angle is established, the slot for the adjuster is cut and the section of wood that connects the top of the handle to the bed is already defined. There is really not much of an allowance to move the infill forward or back before any of these aspects will be fatally compromised. Anyway - it requires all of my wits being present to do this task.

Back on topic. Until now - the rasp and file stage took the longest. I was typically using about 6 different files and rasps for this stage, but it was never quite perfect. One of the issues was finding a tool that would remove material quickly, but do so in a very clean manner. Generally - this is not done with rasps. I love rasps - but the cutting action leaves deep V shaped grooves as opposed to a file which leaves a more level surface. Rasps are great for stock removal - but it is sometimes difficult to accurately gauge the depth of the bottom of the V shaped cut. When fitting infills +/- .003" can be the difference between the perfect fit and disaster. So I turned to files because the surface was more level. The trouble with files - they are much slower and tend to clog up much more quickly - especially when used on exotic woods.

Enter this file made by Toshio Fukazawa.






This was unlike anything I had seen before. The teeth one side were completely unfamiliar. They were not like a rasp or a file... but rather a bit of a blend of the two. They had peaks on them that was rasp like - but they were still flat-ish like a file.



The other side was a little more familiar - like a fairly aggressive single cut file. Another nice feature was both edges were safe - and very well done.

I have had this file for several months now, and when I got it home (it was a gift from a very good friend), there was a rear infill and front bun for a No.4 to fit. I decided to quickly try the unhandled file - just to see what it would do. I was blown away. The toothed side removed wood so fast - I could hardly believe it - but what really got me, was how smooth the surface was. I tried another pass - just to make sure. Same thing - rapid stock removal with a super clean surface. I could hardly contain my excitement. I took of my jacket and kept going. What would have taken 6 rasps and files I was doing with a single tool at twice the speed. Once it was shaped, I flipped over the file and tried the other side. This side was very different. It too cut very quickly, but left an almost polished surface. There was absolutely no clean up after this side. I had both infills fit in record time.

Back to these 7 coffin smoothers. All 7 of them were fit using this single file in conjunction with my Wenzloff saw and small shoulder plane. This process has become much quicker, more accurate and consistent - thanks to this last missing tool being added. The only thing left is to find out where to get a few more of them.

When we first moved to our house in Kitchener - the backyard was quite overgrown. It was clear to us that it had not been maintained for some time. We cleared out 75% of the overgrown shrubs and crooked small trees just so we could see what we were dealing with. There was a very large, Norway maple in the middle of the yard, which had clearly been neglected. One side had been butchered, resulting in the main crotch of the tree holding quite a bit of moisture. A few bold plants had even taken root! We knew it was only a matter of time before things started falling - and last summer we lost a very large branch. I was at Westonbirt in England at the time.

With the current trend towards harsh weather - Jill and I were nervously biting our nails watching from the windows with each thunderstorm.

It was time for the tree to come down.



On August 22nd - the chainsaws arrived and the tree was reduced to a pile of firewood length logs. And even more curious - it came down as I was arriving on the grounds of Westonbirt this year. I returned home to a very sunny backyard. There is an old adage that involves lemons and lemonaid... and in that spirit - this tree removal was a good thing. I grew up with a large vegetable garden in the yard - and I have always hoped our kids would be able to experience this as well. Now we can. There is a great sunny spot along a fence that will be perfect.

Some of the limbs were not cut into firewood lengths yet, and as a bit of a lark, I went into the shop to retrieve a recent purchase - a large Japanese saw. I wasn't expecting much to be honest - but boy was I wrong (and in hindsight - I should have known better!).



This is a crosscut timber saw which I am pretty sure is called a Temagori. One of the first things I noticed was the graduated teeth were frightfully sharp and the balance of the saw was very different. It was really heavy in the toe - but as soon as I placed it on the log - it all made sense.
I started the kerf with the smaller teeth (towards the handle). In this position - the weight at the toe held the saw down. All I did was pull - and as the speed quickened - the larger teeth kicked into high gear and removed a tremendous amount of wood. Because of the angle of the handle - the teeth are forced down just by the act of pulling. I did not apply and downward pressure at all. The second stroke was just like the first - but even easier because the kerf was already started. Binding appeared to be a non-issue. I also found myself feeling for the straightest pull - and once I was focusing on that - the saw did all the work. It was effortless to use really - no downward pressure required - the weight of the saw did the cutting. It is a marvel of engineering. So I just started cutting stuff - as Jill peered from the window just shaking her head.



Here are the markings on the blade.



One of the great things about the saw is the teeth are so large, that the complex geometry is very clear.

Oh, and we have already scheduled a new maple tree to be planted in early October. It will be in a new location - so that is shades the house and our patio table in the summer.

And the tree did get the last laugh in the end. Not only were there huge sections of very curly maple - there was quite a bit of birds eye as well. 14" drawer fronts anyone?

I had the good fortune to attend the Festival of the Tree again this August, and like last year - was not disappointed. The format was the same - camping on the grounds of the Westonbirt Arbouretum, large scale sculptures in a picturesque setting and very fine food prepared by “cheffie” (pictured below drying some tea-towels).



One of the most enjoyable things about traveling is the incredible people - and this year's adventure was no exception. There were many familiar faces to catch up with and just as many new ones. We were set up in the Classic Hand Tools marquee again - situated off to the side of the display area. But judging from the well worn pathways inside - we were certainly not out of sight.



There was a new demonstrator at the show this year - and for all intents and purposes - he stole the show. Steve Woodley specializes in supplying hand hewn timbers for restoration work and provided four days of inspirational demonstration.



He was supplied with 3 oak logs and over the course of the 4 days, managed to square up two of them. I found myself stopping to watch every time I walked by - with several additional deliberate trips to watch his progress. I was struck with the simplicity of the process - and the incredible skill and precision required to execute it properly. Steve taught me two very important lessons about axes. First - he taught me how to sharpen them - and yes - they should look like the backs of your plane irons. Secondly - a mediocre axe is not worth the struggle. He had at least 8 axes with him - all made by Gransfors. These are available in the UK from Classic Handtools or in North America through Lee Valley. Not only is he highly skilled - he is a fantastic guy. His brother lives less than an hour from my house and I am hoping to figure out a way to get him over to this side of the pond. I am working on it Steve.



It was great to see Jolyon Reynolds again this year - he was set up around the corner from Steve. Between the two of them - they had an amazing demonstration.



Mark Hancock and his charming wife Karen were at the show again and were a crucial part of the good natured fun and frolic in the classic handtools compound. There were only a few “safe” seconds for me to capture the above photo before Mark shifted his gouge and showered me with shavings. Typical : )



I was thrilled to see my good friend Michel Auriou again - it had been far too long since our last visit. I always enjoy Michel's insight into toolmaking, steel and business. The best piece of news was that Auriou is back in business. Hopefully some more left handed rasps will be in my future...



David Charlesworth and Pat stopped in on Saturday - it was great to see them again. They were set up beside me which gave us a chance to catch up a bit and talk shop. Here we are discussing one of Bill Carters planes (nice segue, eh?)



That same day - Bill and Sarah Carter arrived. It is always a thrill to see them. Bill had over a dozen planes with him - from wee little 1/2" boxwood smoothers, to an incredible 28-1/2" jointer. Bill was kept very busy with a steady stream of admirers and Sarah kept the three of us content with coffee and homemade cake.



If I had the money - this pair of mitre planes would have come home with me.



Another fine planemaker stopped in for a visit - Christopher Martyn. I met Christopher at last years show and was very impressed with his instrument planes. Some of his planes were featured in Fine Woodworkings 2007/2008 Tools & Shops issue.



My friend Tony stopped in to try a few planes - here he is testing out a No.4 smoother.



I also met Mike Riley and had a great visit with Phil Edwards. The Romanesque fellow is Alex Primmer - he works for Classic Handtools.

It is amazing how much changes in a year. Last year, Phil was contemplating making a few planes - and this year he had his own line of tools and was conducting a brisk business. A few days before I left for England, Phil sent me an email asking if there was anything he could bring along to help reduce my luggage. It was an extremely thoughtful offer and as it turned out - I did use many of his things over the course of the event. My deepest thanks Phil for taking good care of me during the show. I hope I can return the favour in Berea.



Mark Bennett was a new demonstrator at the show and I have to say I was quite impressed. He is a very kind, soft spoken fellow and we found ourselves discussing the finer points of plane design, our respective wood stashes (I suspect his will knock my socks off when I see it) and design in general. I thoroughly enjoyed his company. He was also a wealth of knowledge and passed on several great insights. One of the more interesting one was tree warts. I have to admit I was a little skeptical until he showed me one. He handed me a holly wart. He said they are very tight burls and cuts them into disks and uses them for inlay work. So I now have a Holly wart to add to my growing pile of timber.


Fun & games

The show was not just work - there was tremendous play as well. I sometimes feel guilty about it - and there were two instances where I found myself beautifully derailed.



The first instance was finding a small Boxwood branch sitting on the burn pile (yes, they were burning boxwood!). I have a wonderful Japanese hammer head by Masayuki that is in need of a handle. I have been referencing So's site to learn how to handle a hammer. I cannot find any Gumi - but this piece of English boxwood should be a nice substitute. Philly caught me cleaning up the piece of boxwood for the trip home.



The other derailment was Mark and I cleaning up a large piece of boxwood (with an Auriou rasp of course).



Philly and Mike Riley planting some vile shavings.



Chris Pye being majestic even when he is trying not to be. Chris was set up about 30 feet away but I was able to watch him transform a rather non-descript bit of wood into a very fanciful beast. I only wish I was able to pay closer attention - I know he has a lot to teach and I have a lot to learn.

I also had great visits with John Lloyd and Rob Cosman but did not manage to find them when I was collecting photos.




And last but certainly not least... a rather tuckered member of the International football team who was sadly defeated at the third annual “Billy Hancock Birthday showdown”. The Brits won 3/0. Mark shared a very funny comment on the last day. He was telling a few of us how surreal it was to be the keeper for the British team and seeing all these faces he recognizes from magazine head shots rushing at him. The quote went something like this... “and there was Rob Cosman - with the ball... rushing towards me. Bloody hell!”

I would also like to express my thanks to Mike Hancock, his lovely wife Mary, and their kids Alex and Billy. The Classic Handtool marquee is not the focus of Westonbirt - but it has become a very important part of it - and clearly inspires people to work with wood. Mike has done an outstanding job, and has proven that a vision of something different and a little creativity can make something very special happen. Congratulations Mike.

Back in June of 2007, I had the good fortune of meeting two people on my “list”– Jim Leamy and Paul Hamler. It was a little overwhelming – Paul had his brand-spanking new scraper plane insert – and Jim… well – he had an army of plow planes. Jim and I were set up beside one another – and after the 10th plow plane my jaw started getting sore from hitting the floor. They were amazing – and no offense Jim… but the pictures on your website do not even come close to representing your work. I was pretty smitten to say the least. A funny thing happened as I was standing there admiring them. I really wanted one, but not necessarily to use. It was a strange feeling. I love fine tools – but they have always been purchased because of their exceptional function as well as their aesthetic. I guess this is a testament to Jim’s work, because this time function was a secondary consideration.

During the show, I must have walked over to “planet plow” at least a hundred times –daydreaming of what I would want if I were to commission one. It was harder than I thought. The one plane that really captivated me was the Sandusky center wheel plow. Ok – that was the plane – now what were the specs in this little dream? The Brazilian Rosewood version was fantastic. Brass fittings… or nickel plated? But ooh – the ebony and nickel plated version… sweet. Between visits 56 and 57 I noticed something else – these were all for right handed users. I wondered if plow planes could be made for us sinister folks? So shyly – I asked. Jim’s eyes lit up – a good sign. He told me he had never made a left handed plow – and seemed a little excited about me asking about it. Now this was starting to get really exciting – the possibility of Jim’s first left handed plane. And this seemed to open my mind a bit more – to other woods that might not be as common. The first one that came to mind was African Blackwood. Again – I asked Jim if he had ever made a Blackwood plow. He hadn’t. Hmmm… the plane was starting to spec itself!

Over the next couple of months, Jim and I stayed in touch quite regularly – talking about possible configurations of materials. Brazilian was still on the short list as was Ebony – but Blackwood has a special place with me, and in the end – won out. Jim really thought the fittings should be plated and not brass – and I was quite happy to go with what his gut was telling him.

On January 10th, the first email arrived – he was starting the plane! Shortly after, pictures started rolling in. The first was aptly titled “swiss cheese”. There was a great little touch happening in the background of al