Options for flattening wide panels

[kirkroy]

I've been checking into the various options for flattening wide panels, which for me is anything over ~13". I'd like to see what you guys are doing and why. The obvious methods seem to be: have a shop do it for you (hate this idea, I could just have a shop build stuff for me too), handheld belt sander, handheld power planer, and hand planes (e.g., a jointer plane, like a #7).

The only one of these I can try without buying something is the handheld belt sander option but that has limited appeal (basically, just that I don't have to buy something).

[SARGE..g-47]

I have a 20" planer.. therefore my limitations go to 19 1/2" on one pass. But still the same scenario as I just did two side panels with a top to come that runs over that. I glue up not to exceed my planer width. Then I run the glued panels through and glue the 2 (possibly 3) sections together. That way I have less work with a #7 hand-plane.

I am not a fan of belt sanders other than exterior home work, but that is an option that could be used. You could pay a shop just to flatten a panel with their drum sander if you are not an every dayer and can't see the justification in an investment up-grade.

But.. if you intend to do this for a long time and are going to do lots of large carcasses as I do.. I highly suggest that you get a jointer hand plane and a smoother and learn to use it. That's how I started 36 years ago and if the power goes out today.. it worked well for 5000 years and it will work this again this morning.

Even with large equipment as I am fortunate to have.. there are cases where you still have your hands tied behind your back by not having even larger capibility. Learning to use a hand plane was once a basic.. and it still is even though few recognize that. It delivers enormous ability to go where your power equipment can't go and you are not limited to size.

Well.. unless you just enjoy eating and having sanding dust thrown all over you and your shop. Then... just get a d*mn belt sander.. and wouldn't hurt to get a dust mask and a couple of boxes of filters.

Just the veiw from "Sarge's" world...

[charger1966]

Hello Kirkroy, I also had the same problem. I found the only solution was to Build a Thickness sander. I am right now gathering parts to build it. It will be able to sand a panel up to 26" wide. I feel that is more then wide enough for anything I would be building.
Here is the inspiration for mine;
http://www.woodworkstuff.net/EDTSander.html
Although mine will be driven by a separate motor and have a motor to run the feed conveyor. As soon as I complete it I'll post pictures of it.
Keep Making that Sawdust.
Lance

[poolhound]

Dont use the belt sander it wont really give you the results you are looking for.

Build a thicknessing jig for use with your router. I am nearly finished building a table and wanted a solid top. I bought a 15" x 2" rough sawn board and used such a jig to flatten it. The jig is easy to build and use.

Even if I get boards that will fit my planer (>13") I often do a quick pass with this jig first to take out any major uneveness to save the knives in the planer.

Its a little time consuming and creates lots of sawdust and wood chips but isnt that half the fun.

Jon

[MikeMcCoy]

You can get a couple of vintage user planes as cheap if not cheaper than a belt sander. I have all the typical tailed equipment but I still find getting that initial flat face easier with hand planes. Hand planes won't provide instant gratification but the learning curve is surprisingly low.

[drumpriest]

I have a 16-32 drum sander, and anything over about 24" really, I take to a local cabinet shop and they rent time on thier time saver.

[LinuxRandal]

If you have panels NOW and only need to do this a few times, the router sled would be the way to go for me.

Handplanes are great, but they do take some practice and I am STILL learning proper use, but that would be my next choice OVER a belt sander or small electric power planer.

I looked at the Stockroom supply v sander at the woodworking show (since they didn't respond to my emails). I was able to get my one non addressed concern shown. They showed how to use it as a thickness sander, and since they were selling the kit, with the predone top, I ordered one. (my email was about ordering the top, I ended up contacting them through their ebay account). While it would be a slow process, that will become another option for me.

[jackellis]

I ran into this problem trying to make a top that was wider than my planer and I've concluded that until I have the shop space, I'm going to learn to plane wide panels by hand.

I wish my glue-ups didn't need to be flattened but that's another story for another time.

[kirkroy]

First thing, thanks for the ideas!

I do kind of feel like I ought to develop at least some basic, practical skills with hand planes so there's a certain appeal to that approach. I've found some online sources of refurbished planes and it looks like I could get a decent jointer plane for a fair bit less than $100. Anyone have any good, known sources for buying old planes?

The router sled thing doesn't sound too bad either, although storing the thing in between uses can be an issue in my storage room (aka, workshop). I do have plenty of scrap already so I could avoid having to buy anything but a bigger bit for my router...

[poolhound]

First thing, thanks for the ideas!

The router sled thing doesn't sound too bad either, although storing the thing in between uses can be an issue in my storage room (aka, workshop). I do have plenty of scrap already so I could avoid having to buy anything but a bigger bit for my router...

Something with a wide cutting area is best and saves time. A draw lock bit worked well for me and of course it comes in handy for making drawers

Jon

[LinuxRandal]

First thing, thanks for the ideas!

I do kind of feel like I ought to develop at least some basic, practical skills with hand planes so there's a certain appeal to that approach. I've found some online sources of refurbished planes and it looks like I could get a decent jointer plane for a fair bit less than $100. Anyone have any good, known sources for buying old planes?

The router sled thing doesn't sound too bad either, although storing the thing in between uses can be an issue in my storage room (aka, workshop). I do have plenty of scrap already so I could avoid having to buy anything but a bigger bit for my router...

As for WHERE and WHO to buy planes from, I bought one and have heard nothing but good things about Clint Jones, over at SawmillCreek. (I BELIEVE, Leonard Bailey at Woodnet is the same person). They arrive cleaned and tuned and ready to go.

As for the router sled, some years back I saw a plan for an inexpensive one. They drilled a couple of holes in some boards (same location) and ran two steel rods through the routers edge guide holes in its base. then it slid along it and you set the plunge depth and locked it at that.

Or, part of my storage solution is to hang things between the rafters.

[MikeMcCoy]

Kirkroy - browse the Handtool Forum at Woodnet. There are several regulars there that restore and tune planes so they are ready to use out of the shipping box. I've bought several there and if I recall, the most I paid was $75 for a jointer plane. A couple that I've received compared favorably with my Lie-Nielsons.

[Wood_workur]

Dont use the belt sander it wont really give you the results you are looking for.

Build a thicknessing jig for use with your router. I am nearly finished building a table and wanted a solid top. I bought a 15" x 2" rough sawn board and used such a jig to flatten it. The jig is easy to build and use.

Even if I get boards that will fit my planer (>13") I often do a quick pass with this jig first to take out any major uneveness to save the knives in the planer.

Its a little time consuming and creates lots of sawdust and wood chips but isnt that half the fun.

Jon

agreed for the jig. mine was made out of some scrap redwood, and it worked really well. I used some pine that went into another project to support the jig, and I flattened my guitar body pretty well.

[eddy merckx]

Absulutely try out a hand plane or two Kirkroy. A well tuned plane is really a joy to use. With a little practice, you can flatten a panel pretty quickly. I have read some experienced users say that they could do almost any flattening with a #7. It does go faster if you hog off as much material as possible with a jack plane first, then follow with the jointer. Jacks (usually #5) are even cheaper and really versatile. You might also want to consider a #4 for smoothing, although you could do that with a ROS.

Old planes are still an unbelievable bargain. Some day that will probably be all snapped up, but for now they seem to be available in unlimited quantities.

You'll also need to get familiar with sharpening. Lots of good options for that, but there is a learning curve there too.

Eddy

[kirkroy]

Eddy, you've actually hinted at one of the things that kind of scares me about hand planes, always wanting another one... I'll go ahead and get a jointer plane for now and do some learning (sounds like there's a lot of learning curves with tuning, sharpening, using). I like the idea that using planes is even more of a hands on process than power tools...

I made a router sled last night out of an old plywood headboard. I tried it out with my nicest bit, a 1/2" CMT, on a 20" wide piece of glued up red oak which I've been experimenting on. I was surprised at how nice the surface turned out (obviously needing clean up but not bad). I'm definitely gonna need a bigger bit though.

Kirk