LumberJocks

Orchard Street Sofa #2: Starting the Arms

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Blog entry by AandCstyle posted 02-15-2016 12:56 AM 1124 reads 1 time favorited 12 comments Add to Favorites Watch
« Part 1: Getting started Part 2 of Orchard Street Sofa series Part 3: Kinda got stuck today »

I leaned heavily on the Paolini video for making the arms since bent lamination is a new adventure for me. He suggested resawing the laminations for the arms starting with the table saw them finishing cutting them with the band saw. My blanks were just about 1.125” thick and I wanted to get 3 lams from each blank, so I switched to a thin kerf blade.

Remember to keep the same side of the blank against the fence. I recommend a high fence to eliminate any chance of the stock tipping as it is being pushed through the blade. On to the band saw for the final cut for each lam.

After the lam is cut off, I needed to run the blanks through the planer to get a flat surface to push against the TS fence. Repeat the above until all the lams have been cut and planed to 1/4”. While resawing with the TS wastes a bit more wood than I would like, it is a good way to prevent the BS blade from wandering-not that mine ever has. ;)

I stacked the lams to prevent any warping if possible and so far, so good.

My next step was to make the bending form. Paolini drew a baseline on the plans and ticked off 1” increments, then measured the distance from the baseline to the bottom of the arm profile at each increment. Next he drew a new baseline on a 6” wide piece of particle board and again ticked off 1” increments and marked the appropriate height with lines perpendicular to the particle board base line. Then he connected the dots and cut about 1/8” outside that line with the BS. Finally, he faired the curve with a horizontal belt sander. I followed his guidance and you can see my rendition.

I think the photographer was out to lunch for the above segment. :/

After that, it is simply a matter of marking the 7 additional particle board strips and cutting the curves with the BS.

After they are all cut, glue and nail one of them to the original and run them across the router table with a bearing bit aligned with the faired piece.

I gotta get a dependable photog!

Attach a stop at one end and on one side of the form and cover it with tape so the glue won’t stick to the form. I used 1/4” melamine for the side.

The hardest part of this was lugging the particle board form around, it must be about 50 pounds when complete. I had a few minutes before quitting time, so I cut the side slats to final length. I used a stop to ensure they were all the same length.

More tomorrow if all goes well. Thanks for reading along.

-- Art



12 comments so far

View Alongiron's profile

Alongiron

569 posts in 2155 days


#1 posted 02-15-2016 01:03 AM

Great stuff Norm!! ....I mean Art !! Lol

-- Measure twice and cut once.....Steve Lien

View Mark's profile

Mark

819 posts in 1436 days


#2 posted 02-15-2016 04:31 PM

Starting to get interesting. From what little I can see, it looks like you’ve a nice sized shop to work in. Troubles with the photographer??? I know exactly what you mean. It’s so hard to get good help.

-- Mark

View CaptainSkully's profile

CaptainSkully

1430 posts in 3020 days


#3 posted 02-15-2016 05:06 PM

Hey Art,

I’m more interested in the woodworking than the photography. Don’t sweat it…;^) The bow arm Morris chair is on my bucket list. The cool thing is that you’ve already invested in making a nice bending form, so you can build chairs in the future at your leisure.

-- You can't control the wind, but you can trim your sails

View AandCstyle's profile

AandCstyle

2566 posts in 1719 days


#4 posted 02-15-2016 10:39 PM

Steve, I wish I was half as good as Norm.

Mark, the shop is a little tight in a few areas, but it works okay. Apparently, I can’t fire the photog because he is family.

Captain, somehow bending forms and leisure don’t belong in the same sentence IMO. ;)

-- Art

View Luddite's profile

Luddite

171 posts in 700 days


#5 posted 02-16-2016 12:58 PM

Art,

Looking really great so far. Thanks for sharing.

-- T Loftus -- Just on the edge of common sense

View RobS888's profile

RobS888

1984 posts in 1307 days


#6 posted 02-17-2016 03:07 AM

Great work, I have the plans Paolini used and I’m getting ready to make 2 chairs. Curly red oak for my wife and white oak for me, so I’m really thrilled to see you using these plans for the sides.

-- I always suspected many gun nuts were afraid of something, just never thought popcorn was on the list.

View CaptainSkully's profile

CaptainSkully

1430 posts in 3020 days


#7 posted 02-17-2016 05:03 PM

Hey RobS888,

Please feel free to blog about your build too! We need more Arts & Crafts stuff on this site :)

-- You can't control the wind, but you can trim your sails

View AandCstyle's profile

AandCstyle

2566 posts in 1719 days


#8 posted 02-18-2016 12:16 AM



Great work, I have the plans Paolini used and I m getting ready to make 2 chairs. Curly red oak for my wife and white oak for me, so I m really thrilled to see you using these plans for the sides.

- RobS888

Rob, the drawing is good or, at least, I haven’t found any errors yet. The written instructions aren’t all that helpful, IMO. Good luck with your build.

-- Art

View RobS888's profile

RobS888

1984 posts in 1307 days


#9 posted 03-01-2016 05:06 PM


Great work, I have the plans Paolini used and I m getting ready to make 2 chairs. Curly red oak for my wife and white oak for me, so I m really thrilled to see you using these plans for the sides.

- RobS888

Rob, the drawing is good or, at least, I haven t found any errors yet. The written instructions aren t all that helpful, IMO. Good luck with your build.

- AandCstyle


I noticed that! I have watched the videos and that is a great help. So is your blog.

-- I always suspected many gun nuts were afraid of something, just never thought popcorn was on the list.

View AandCstyle's profile

AandCstyle

2566 posts in 1719 days


#10 posted 03-01-2016 09:54 PM



I noticed that! I have watched the videos and that is a great help. So is your blog.
- RobS888

Don’t hesitate to ask (PM) if you have any questions when you start your builds.

-- Art

View RobS888's profile

RobS888

1984 posts in 1307 days


#11 posted 03-04-2016 06:27 PM


I noticed that! I have watched the videos and that is a great help. So is your blog.
- RobS888

Don t hesitate to ask (PM) if you have any questions when you start your builds.

- AandCstyle

Thanks, that is a kind offer.

-- I always suspected many gun nuts were afraid of something, just never thought popcorn was on the list.

View AandCstyle's profile

AandCstyle

2566 posts in 1719 days


#12 posted 03-04-2016 11:38 PM

Hey, Rob, that is the purpose of the forum.

-- Art

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