Shaping an A2 jointer front bun
This plane is not finished yet - I have another 4 coats of french polish to apply to the infill before I assemble the plane, but I thought I would do a short sequence on shaping the front bun.
I start off with a solid block (in this case Honduran Rosewood) and mark out the rough bun shape. I always leave plane parts about 1/8" over sized to give myself some wiggle room. In this case, there is a void in the top corner that I am hoping will be removed during the process... but I do want to stay as close to it as possible - there is a great bit of burl right beside it.
The fitting process is pretty simple - plane to fit. I am always thankful that I have infills to make infills.
Here is the block for the bun, fit to the shell. It is a very snug fit - I could take the plane out of the vise and pick it up by either the block for the bun, or by the handle.
The next step is to establish the shoulder where the infill transitions into the top edge of the bronze sidewall. This is done with chisels and then refined with a scraper and sandpaper.
A close up of the shoulder.
The above photo looks like I skipped a bunch of steps, but all this shaping is done on the bandsaw. I use my bandsaw a little like a shaper because it is very fast and accurate. I cannot imagine doing this type of work with a router or shaper (or any rotating cutter). I suspect the nature of their cutting action would mean I would have to work with fairly bland straight grained wood.
At this stage, I have done a fair amount of file work to refine the shape further. I have also started some of the sanding.
Here is the finished front bun. Below are some detail shots showing some of the amazing grain.
And a few photos with 8 coats of french polish..