Tote repair
It is common to find handplanes in the wild with damaged totes. The direction of the grain leads to breaks under stress. But we are woodworkers and should be able to repair something as simple as a tote. Here is a Stanley Bedrock that I found.
One bounce on the floor will usually result in a cracked casting (fatal) or a cracked tote horn (bad, but repairable).
The first step is to remove the tote and examine the break.
It sheared off unevenly along the grain lines. It has quite a bit missing and that part of the horn is important. The curve in the horn catches the web between your thumb and index finger and prevents you hand from riding up the tote. Sheared tote horns might seem minor but they seriously affect control and use of the plane.
Mr bandsaw helped by making the break into a clean cut.
Here is the tote alongside some donor wood and covered by a pattern tote. Rosewood is hard to find and I am allergic to it anyway. Walnut makes a nice substitute.
And here is the glue up.
I use Titebond III for gluing totes and have been happy with my results. Others prefer epoxy. There are a few tricks I use for a good bond. First, I make sure the parts fit well. Sometimes broken totes have been used for years and the pieces do not fit well together. These generally make a poor bond unless they are carved or cut to fit. Flat surfaces work better. In addition, I let the glue soak into the rosewood before clamping. Titebond has a solvent (water?). Rosewood is dense. If you clamp before the glue has soaked in, you will starve the joint. I let it sit for five to ten minutes. Sometimes I even add more glue to the surface. Anyway, the true test to the glue joint is working it. If it stays in place while you work the piece down to size, then the glue joint will hold during use.
After drying overnight in the woodscrew clamp, here is what we have.
That's a pretty big stick for sure. But a larger piece is easier to clamp and more importantly, a large piece means less waste of the donor material. Mr bandsaw helps liberate the tote.
So here is where we leave our tote repair. I will continue shaping this afternoon but first, I need to take a nap. Stay tuned.