Originally Posted by
Nicholas Lawrence
A very true statement. If you rely on the cheery voices you sometimes hear on the Internet about how easy it is to prepare rough lumber by hand, you will become a little aggravated. It is harder than some people make it sound (both in terms of skill needed, and the actual work involved). An old friend who knows a lot about hand tools (but largely uses power tools as a commercial contractor), told me when I started out that I needed to remember that the old timers who made their living with hand tools did build wonderful furniture, but they also spent a lifetime acquiring the skills to do that. As a hobbyist I have no illusions that I will approach the level of skill needed to make things I see in museums purely with hand tools.
I do use hand tools only, because I simply do not have space for power tools (my motley collection of Stanley and Sargent tools also cost me much less than a tablesaw as well; you will not find this to be true if you spend much time looking at the Lee Valley or Lie Nielsen catalogs, as the cost of those tools adds up very quickly). I also like my children to be able to be around me when I work in the shop, and the quiet, lack of dust, and much lower risk of somebody losing an important part of their anatomy makes that possible with hand tools. None of the stuff I make is going to be in any museum, but my wife and children claim to like them, and I have yet to build something I am ashamed of. I look at the imperfections as a record of things I have learned.
If you want to do things completely by hand, I recommend a full sized rip saw as well as a crosscut saw, at least one good saw bench (you look like you have the space to probably make two, which would be better), a scrub plane, and a regular jack plane set up to do relatively coarse work. Your number seven makes a nice jointer or trying plane, and your number five can be set up to work well as a jack. You can get by without the scrub plane, but I find that when I need to remove a lot of stock quickly there is simply nothing like it.
If you want to build a good, cheap saw bench, Chris Schwarz published free plans a while ago that work well, and you can make the whole thing from a single 2 x 8. You obviously will need chisels and other tools as well to do the actual joinery, but what I have listed will allow you to take a rough board, and turn it into parts for whatever you want to build.
You will want to use the "coarse, intermediate, fine" approach if you are preparing rough lumber. Use the saws to break the stock down to size (I think you will find it is much easier to flatten and square multiple small boards cut from a large board than it is to flatten and square the large board and then cut it up into the smaller boards). Then use the scrub plane or jack plane to remove twist and wind, and to get close to your final thickness. Then switch over to the try or jointer to get your final dimensions. The smoother should be taking very little, simply to clean up the surface.
The two tools that made it possible for me to go from using mostly s4s lumber (and largely living with any twist, etc., that may have developed in it) to using rough boards (which are cheaper, and allow me more choice in species and dimensions) were the saw bench and the scrub plane. My sawing is much more efficient and accurate with the board held at the proper height and the saw at the proper angle, and instead of spending hours removing material with a plane set for finer cuts, the scrub plane will remove 90% of a problem areas in a matter of minutes.