I just got my hands on a Woodriver #5 jack plane and found a couple of things that I'm a bit concerned about. First, the sole appears to be slightly cupped from side to side, with the edges sticking out a bit. When I use a 0.002 feeler gauge with a straight edge, it slips under the middle of the sole but not near the sides. Is this a common issue? If not, what's the standard flatness tolerance for the sole? Second, the blade seems out of square against its own edges – while the sides are parallel, one side of the blade's primary edge sticks out a bit. What should the squareness tolerance be for a new blade? Are these problems typical, and should I fix them myself, or would it be better to return it to the Woodcraft store for an exchange?
5 Answers
Both issues sound like they fall under warranty, so definitely consider returning it. You shouldn't have to fix a brand new plane!
If the shop is nearby, I'd suggest exchanging it. Both of those issues can generally be fixed, but if you're not confident in doing that yet, just get a replacement and make sure to check the new one before leaving.
From what I can tell, what you're experiencing is pretty common. The squareness of the blade isn't usually a big deal; it can shift when sharpening. You can easily adjust it using the lateral adjuster. As for the sole, if it's touching at the ends and just in front of the mouth, you're likely fine. I wouldn't return it unless it was really bad in the middle, since that’s tougher to fix.
Brands like Lie-Nielsen grind soles to about 0.0015 tolerances, while for your plane, I’d expect it to be a bit less. I've got some vintage Bailey jacks and I've never fine-tuned the soles. For a jack plane, it doesn't need to be as flat; that precision is more crucial for a smoother like the #4.
Honestly, I'd return it. Even though those issues can be corrected, you shouldn't have to deal with problems on a premium plane right out of the box. You deserve better quality.