Reply To: Can an aluminium shooting board guide rail abrade the edge of a shooting plane?
Have you considered using JB Kwik weld to patch and fill the wear on the plane sole? One option is to fill, then work it back to the proper size, probably with a file and abrasives. Another option is to place your trust in a mold release of some kind, apply the JB Kwik, and place the plane into the chute so that you cast an exact fit. That could go horribly wrong, obviously, but a continuous layer of wide tape or creased paper might do the trick? Another alternative is Bondo. We used to patch fixtures in the shop all the time with Bondo. Usually, we would overfill the defect, wait for partial hardening, trim with a cutting implement while still soft but very well along setting. The goal is to take as much off as possible but still be too large, let it really set, and have a minimum left to sand to the exact shape and size.