It will also serve to tell you why
very little of this kind of work is done. It simply is too expensive
to be cost effective.
It requires the expertise
of a welder and a machinist. Neither of these is cheap. So if you
decide that you want to proceed with such a repair, you have been
First is a picture of the
plane as I received it.
It had 15 holes drilled in
it to hold in the infill wood. I suppose there was no epoxy
available when this was done.
There is a crack through
the side wall of the plane running from the center of the mouth to
the top. Next is a close up picture of the crack.
Next is a picture
showing that the crack went right through the tapped hole which the
plane shoe bolts onto. This had to be ground out and filled with
brass, then machined flat, then drilled and tapped.
I ground the crack out
starting on the inside of the plane so as to minimize the size of
the groove on the outside which will be visible.
I ground it about ¼” wide,
and not quite through the wall. This will support the brass as it is
You can see the depth of
the groove in this side view. The tool I used to grind out the crack
is a 1/8” diameter Dremel carbide bit.
Welding lore has it that
you never use an abrasive on cast iron you intend to weld. I don’t
know if it is true that the abrasive remains on the metal or not,
but I believe the lore, and I do not use abrasives on cast.
The next picture shows the
outside ground out after the inside was brazed. Please notice the
discoloration of the base metal. I raised the temperature of the
entire piece to about 1000 degrees before I brazed it. This is