Inspired in one Paul's Sellers collection hand planes, I decided to make my own one as similar as possible in an easy way and using hand tools. In this video you can see the step by step.

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I would also apologise for my English as a non-native English speaker some terms are very difficult for me. Forward, inscrutable!!

Step 1: Materials and Tools

Materials

Sycamore wood
Quality Brass sheet (1,6mm/0,06") thickness
Insert rivet nut (M6) 0,35" Amazon USA UK
Blade plough plane (10mm/0,39")
Sapeli dye and Wood wax
Thumb screw

Tools

Handsaw
Hand plane No5 & Block plane
Engineers Square
Gauge Veritas
Chisels
Clamps
Japanese Saws
Angle Level and ruler
Scrapers
Veritas Dovetail Saw
Rasps and Files
Gouge cut 3 straight
Sanding Paper grit 250
Fret saw
Cabinetmaker’s Hammer
Electric drill and Bit drill (9mm) (0,35")
Paper joining tape

Step 2: Cutting the Main Piece

For this project I used Sycamore wood since this is a resistant and hard kind of wood. I have made it, as almost always, hand tools but you can replace them by power tools.

I began cutting one side of the wood and planing it with a hand plane. Once straight with the help of a gauge I marked the rest of the parts to cut. I repeated the previous steps in order to obtain a completely square wooden block.

Step 3: Marking and Cuttings

We have to mark an angle between 45 and 50º as per photographs and we cut it wihout reaching the end.

Then clean the saw-toothed marks leaving a smooth and plane surface.

Step 4: The Blade

With the help of a ruler mark the centre of the piece and introduce the blade that we'll use for our router plane. In my case I used an old plough plane blade of 10mm/0,39". Mark the contour and eliminate the wood where we'll introduce the blade with a chisel.

Step 5: Cutting

Now we have to cut a wide enough surface to see the blade path when we're working. I chose triangular shape but it can be used any other shape.

Step 6: Oval Shape

In order to give the router plane a more ergonomic shape, I give where the thumbs will be supported rounded shape with the help of gouge cut straight

Step 7: Lever Cap

Now we have to make the lever cap which will hold the blade. I make a template with the help of paper joining tape and later I glue it on a brass plate. Cut the piece and file down the edges until it's smooth.

Step 8: Drilling the Brass

I drill 4 holes for the fastening screws and another one of 9mm/0,35" in the middle for the rivet nut. As I don't have the necessary tool for the rivet nut, I use for it a hammer as you can see in the video.