Several months ago, I bought an old wooden router at an antique store for $20. The price tag said it was a Japanese woodworking tool. I guess it could be if a Japanese guy used it. Looked like a home made wooden router plane to me. I bought the tool simply for the hardware, and the Stanley router bit it that came with it.
I search online and came up with a wooden router plan and printed it out. Then I measured, drew, and bore the three holes for the body on a piece of 2″ thick cherry.
A few minutes on the band saw I had the new body of the router.
The hardest part in making the body was cutting the mortise for the blade holder. I jabbed at the wood with chisels, knives and drill bits in order for the piece to fit. I ended up getting the piece in the hole and then tightening in the back in order to crush the wood fibers into shape. It took a few attemps, but after a few minutes, it finally fit.
Once the hardware was in, I stuck the blade back in to see how the final fit. Once I was satisfied, I sanded the body and applied a few coats of shellac to it.
The last thing I needed to do was sharpen the blade. The easiest way I have found to sharpen a router plane blade is to grind a bevel on an oscillating spindle sander making sure to take a light touch in order to prevent burning the edge of the cutter. Then, I hone the edge and flatten the back with a whetstone.
I stuck the blade back into the router to see how it cuts. Cuts like butter!
If you’re in the market for a router plane, take a look at the wooden versions. They are much cheaper than their metal counterparts as some of their prices fetch up to $150. I see wooden router planes all the time at antique shows for around $40. They work pretty much the same way, they just don’t have the adjustment mechanism to raise and lower the blade. With a little practice, you can easily tap the blade down with a hammer to lower the blade for the next cut.