Posts Tagged ‘2500’

In our previous post, we discussed using other manufacturer’s cutters in our 2500 router plane.  Why would you want to use another manufacturer’s cutter?  Because right now we only have one size, 1/2″ square tipped.  We may offer a spear point, possibly one other size like 5/8″, but that may be a little while and we currently have no plans to offer the wide range of sizes companies like Veritas produce.  Fortunately, it is possible to use many other cutters in our router… unfortunately it requires a permanent modification to that cutter: adding a secondary notch.

Adding the second notch isn’t hard, but take your time and check the fit often.

The reason for this second notch is simple; without it you won’t be able to take a cut less than 1/2″-1″ deep depending on the cutter you’re using.  That’s not good considering almost any cut you’d want to make with a narrow blade will tend to be very shallow.  (This is usually where people ask why we didn’t just make the threaded posts taller like other router planes… it’s because the 2500’s cutter can move to the side positions and a taller post would stick up through the handles, so they have to be somewhat short.  This is true of the original Preston design as well.)  So, by adding a secondary notch you can use many other manufacturer’s blades.  Lie-Nielsen is a no-go because they use a square shank, but any diamond shank measuring around 3/8″ square should fit.  To make this notch you will likely need to use a Dremel tool with a grinding wheel which can be further refined with diamond files if you have them.  Standard files won’t work (at least not on Veritas’ cutters) as the shanks are heat treated.  Work slowly, keep the notch as square as possible, and check your progress frequently.

A variety of cutters, from left to right: a vintage Record, an unaltered Veritas, the WMT cutter, and finally a modified Veritas.

The notch is technically 0.155″ tall and 0.130″ deep, but that doesn’t really matter.  What matters is making it just tall enough to fit around the depth adjustment nut and deep enough that it won’t bottom out on the adjustment nut.  There should be clearance all the way around the nut when installed and clamped down.  The position of the notch is about 0.8″ below the top notch, but that’s on the Veritas cutter.  It may differ on other cutters based on how tall the shank is.  Basically make the notch such that the adjustment nut keeps the cutting edge of the blade slightly above the sole of the tool (so no cutting occurs) when it’s at it’s maximum height.  Then as you lower the nut, you start to take a cut which naturally gets thicker as the nut drives the blade lower and lower.  When you bottom the nut out on the body of the tool, you should be able to move back to the upper notch and continue.  It’s a good idea to layout the notch and check all these positions before actually cutting the blade.

Location of the second notch, just under 13/16″ below the upper notch for a Veritas cutter.

This vintage Record cutter would also work well in the WMT 2500 router.

Now for a few important notes, disclaimers, etc.  The most obvious thing to state here is you’re modifying these cutters at your own risk.  Second, the Veritas cutters neck-down on the shank width fairly high up which means you aren’t getting the usual amount of support for the cutter when it’s clamped in the tool.  As a result, you may find it doesn’t align perfectly straight every time or can shift if pushed on hard enough.  For me, this has been a minor inconvenience at the most.  I make sure the blade is straight as I clamp it in place, if it’s not I simply turn it slightly with my fingers until it looks good, then clamp it down.  At that point it shouldn’t shift.  Yes, it’s possible if you push on it sideways with high force, but small blades are typically only going to see light forces and usually take them head on, not side ways.  Finally, you obviously can’t rotate the cutter 90 deg in the side positions simply by adding a notch.  This is true, but I would ask why would you want to?  Smaller cutters are generally for smaller work so using it in the standard middle position is ideal.  For larger sweeping cuts where the 90 deg rotation is desirable, use our cutter.

Note the narrowing effect of the Veritas cutter.

This is roughly the starting point for the blade where a flush cut would be taken. Notice how there isn’t a lot of supporting material on the shank to align the cutter in the V-groove.

The narrow cutter installed with the added notch. Not too shabby.

And that’s all there is to it.  A small change to cutters many of you probably already own or can purchase at a reasonable price and routing in any sized area becomes nbd (that’s “no big deal” folks).

-WMT

It’s been several months since the last router-related blog post, we were busy finalizing the prototypes and preparing for two Lie-Nielsen events we just wrapped up in Philly and Cinci.  So a quick status on the tools: pre-orders are now available on our site as most of you know already and we’re just waiting on our final pattern changes to come in so we can place our production order at the foundry.  We will soon be finishing our cutter prototype and ramping up production on everything else.  Tools are set to begin shipping in June.

Now for the overview of blade positioning in the 2500 router.  This is by far the most distinguishing feature of the 2500 when compared to the #71 that Stanley made so popular.  With the 71, the blade mounts in the center and can, in certain versions of the tool, be mounted on the back of the center post to give an open throat or bullnose style setup.  Preston’s 2500P could mount the blade in four locations: standard closed throat, reverse open throat (or bullnose), inboard of the right-hand post, and outboard of the left-hand post.  When mounted on the left or right-hand post, the cutter could only face to the left, perpendicular to the standard direction of cutting.  This allowed the tool to be pushed sideways, presumably for working on narrower edges or in situations where a short-wide sole interfered with something on the work piece but and long-narrow sole did not.

blade in the standard closed-throat position

Blade in open throat position

Inboard position on right-hand post

Outboard position on left-hand post

The WMT 2500 router maintains the same four blade positions, but we’ve added the ability to rotate the cutter in 90 deg increments when positioned on the left or right-hand posts.  This allows the user to hang to tool over an edge and make sweeping cuts, such as when working with tenons.  Many woodworkers have done this with the 71, but you can only go out about 1.5″ before the tool becomes unstable.  Then the standard practice is to support the other end of the tool with a block of wood that matches the height of your work piece so the tool doesn’t tip… of course problems arise if the support block isn’t exactly the same thickness of your work piece.  You also have to take the time to get a piece of scrap and size it accordingly.  With the 2500, you can simply move the blade to the side position, rotate the cutter 90 deg, and hanging the tool out 5″ or more is no problem.

Cleaning up a large tenon with the cutter rotated in the outboard position.  Note how well the tool is supported on the work piece despite the fact that this tenon is over 2.5″ long.

Before wrapping this up there are a few details I’d like to point out.  First is simply that the cutter shown in these pictures is not our production design.  We are still finishing the prototype and will cover that in more detail once it’s ready.  Second is that the minimum depth of cut is limited when the blade is in the outer post positions AND rotated 90 deg.  The tip of the cutter needs to stick down almost 3/16″ so that the top of the cutter clears the sole of the tool.  At first glance you might think, “Why not machine a pocket into the body of the tool that the cutter recess into?” And that’s a fair question.  Here’s why we left it alone.  Machining into the sole that deep and that wide breaks through the inner corner of the casting and looks awful.  Adding more material in that area to prevent this also looks confusing and poorly designed.  Next is cost.  Milling a pocket in the side of the tool would require another setup and more time which means more money.  But the final and most important reason for not bringing the cutter higher into the body is because it really didn’t seem necessary.  Small shoulders (less than 3/16″ deep) are typically found on smaller scale work where the tenons don’t stick out very far, simply use the tool in its normal configuration.  Long tenons, where you’d want to move the blade out and overhang the work piece quite a distance, are typically found on larger scale work which means the shoulder will generally be 1/4″ deep or more and the minimum depth of cut won’t pose any problems.

Until next time, -WMT

WMT will soon be releasing our newest tool, the No. 2500 router plane, which is based on the Preston 2500P.  Because there are so many details to cover on this tool we will be sharing a series of blog posts roughly once a week, each of which will cover one readily digestible chunk of information at a time.

I’d like to get the fundamentals out of the way up front before talking about the features and benefits of the tool compared to what already exists today, so lets get started.  First are the physical dimensions of the tool.  As far as we know, our router plane will have the largest footprint to ever hit the market.  When studying several new and vintage planes, most of which are based on the Stanley No. 71, their soles ranged in width from 5-5/8″ to 8-1/4″ with the average measuring about 7-1/2″ wide. However, these planes all have soles that are longest in the center and then diminish as you get towards the outside edges of the tool.  This makes the tool less useful when straddling a large surface, such as leveling the face of a tenon.  The length of the sole on the Preston, which measures slightly more than 8-1/4″ wide, remains constant over its width (aka: a rectangle).  The sole of our router plane was bumped up to an even 8-1/2″ x 3-1/2″.

The Preston 2500P body compared to the widest 71-style we found, this one from Millers Falls.

The Preston body compared to the narrowest body from Veritas which measures only 5-5/8″ wide.

And while some may think a small sole is no big problem because a secondary wooden sole can be attached to most planes making it any size you want, you’re correct… sort of.  A secondary sole is one more thing you have to make and you need to keep it as thin as possible so the tool’s depth of cut isn’t greatly reduced.  However, a thin secondary sole that isn’t well supported will deflect, which can make the cutting action of the tool range from problematic to useless.  By having a large rectangular sole, adding a secondary sole isn’t as necessary, but when it is desired it is well supported even at a minimum thickness.

The next detail is one of the thing’s we’re most excited about: offering the tool in manganese bronze.  Again, as far as we know, this is a first among router planes.  The bronze not only looks fantastic, but there are the added benefits of extra weight (this will be the heaviest router plane ever sold) and zero concerns when it comes to corrosion.  It was not easy to find a suitable foundry for casting this tool in bronze, but persistence paid off and we’re proud to make it our mainline offering (we may or may not offer ductile iron in the future).  The non-bronze components will either be brass or stainless steel, with the one obvious exception of the cutter which will be O1.

One final detail I’ll throw in is our removal of one part of the original Preston design.  The doo-hicky (that’s its technical name) on the front is quite confusing in appearance as well as function.  It is comprised of a small casting which can move front-to-back in a pair of slots and is locked down with two small screws.  Once locked down, a threaded post can be raised or lowered, then locked in position.  I figured this could be used as a crude depth stop, but then why make it adjustable front-to-back?  I emailed Paul Sellers about this as he’s a big proponent of the Preston style router (and if you don’t follow his blog I’d recommend it) and he said it was designed as a guide when running the tool in a recess to prevent the cutter from gouging the side wall.  I still don’t understand why it needs to slide a fraction of an inch in slots though… possibly as a throat-closing device of some sort as I read some speculate online, but this seems like a poor way to go about it and downright unnecessary.  The added cost and tools required to make an adjustment made it hard to justify keeping in our version of the tool.  It also blocks visibility and isn’t included in Preston’s 1399P model router, so we decided to eliminate it.  If you’re wondering why ours is a model 2500 and not a 1399, it’s because we are including the adjust fence which was never available on the 1399P.

The awkward adjustable gizmo on the Preston 2500P.

That’s all for now, but we still have knobs, cutter configuration, cutter orientation and more to discuss in the following weeks so stay tuned.  And as a status report, our patterns are being made and hardware is being prototyped.  We should have the hardware within a week, but the patterns will take roughly a month to complete.  Then we’ll get our first look at the castings.

-WMT