Thinking Cane Part 3

3/12/2013 - Wow, it's been over a month since I last posted.  In that time I bought two 1" x 1" x 5' sections of aluminum to make another set of planing forms that should hopefully last a bit longer and will be more durable.  I bought the aluminum well over a month ago and right away began filing each face of the bars. 



Here's the two bars clamped and ready for filing. 
 

As you can see in the picture above the bars are clamped together with some C-clamps and then flipped over and then the filing begins.  The first face to be filed is the part of the form that will be facing the inside of the form.  The filing takes away any imperfection and unevenness that shows up in the metal.  These peices must be in all sense of the word "perfect" so that the rod has the proper feel as it is cast and used while fishing.  For more information on how these forms are made you can refer to the following links

       http://www.thomaspenrose.com/form01.htm
       http://www.bamboorodmaking.com/html/wood_planing_forms.html
      

After a long tedious filing session the two bars are ready for drilling and tapping each station.  Each bar is 5' long.  Each station on each bar is 5 inches apart.  Starting one inch from the edge I then measured each station in five inch increments.  After each increment is marked the bars are then placed on the drill press and then each hole is drilled.  I used a 1/4" drill bit and proceded to drill each hole completely through both bars.  After the holes are drilled I used a 5/16" drill bit and enlarged the holes on the bar that was going to do the sliding as the form is open and closed.

Holes being marked prior to drilling

As you can see in the picture above the holes are being marked for each pull station.  The push stations will be marked in the same manner as above.  In the picture both the push and pull stations will have threads tapped on the same side.  On the opposite side of the form the pull hole will be enlarged as I stated above so the form can slide as it is pushed open and as it is being pulled closed.  Remember to take your time as you drill each hole.  Here precision is the name of the game.  If you're not careful you will ruin the form and you'll have to scrap it and then start all over.  So remember slow and steady wins the race.

The form finished in all it's glory

Here each hole was drilled then tapped and all the bolts placed and the form tightened down.  When this step is complete each of the planing surfaces are again draw filed.  This is a one of those other long and tedious steps in making the form.  After this step is complete I then losened each pull bolt about 1/4" then tighted down the push bolts separating the two halves of the form.  From there I went to each pull station and measured IN 0.006" then tightened each bolt at the desired measurement.  As I went up the form towards the butt I moved each station in again at the distance previously stated.  This gives a rough taper of 0.001" per inch as you move up and down the form.  From there I took a triangle file and made a tool to file the 60* groove in the form.  This is the most labor intensive part of the whole process because as the form is closed the groove becomes deeper.  When no more material can be removed from the file congradulations you're finished.

Please keep in mind I am NO EXPERT and I couldn't have completed this project without referring to the websites I refered to above.  I took bits and peices from all the sites and all the bamboo rodbuilding forums and made my forms.  At first is was very confusing with all the different numbers being thrown at me but eventually I got it.

Again, if you wish to make the form use the links above as they are loaded with great information on how to make one of these forms.

Randy