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Designing a Chair #3: Chair III: 1st Bent Lamination

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Blog entry by Dave Rutan posted 10-25-2014 09:22 PM 1364 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 2: Chair II Part 3 of Designing a Chair series Part 4: Chair Saga Part IV »

Last night I grabbed some particle board that I have in the shop and made a bending jig for the chair back. The chairs are for the table I made for our church. Although I’m glad I had the particle board to use instead of ‘good’ plywood, I got really frustrated with my band saw while cutting out the bending form. Lately I’ve been getting along with my bandsaw but this was miserable. I cut the curve out of two boards and the switched to my jig saw because it’s always worked well for me in a pinch. There must be something in this particle board because it dulled two jigsaw blades cutting 4 boards. I have no idea how the bandsaw blade fared, but I wouldn’t be surprised if I end up getting a new blade.

So the photo above shows my first attempt at bent lamination. I’m gluing together 4 strips of 3/16 inch plywood. The plywood is recycled stuff from a drawer bottom I got somewhere. I’m using Elmer’s wood glue for this. I also wet the wood down before gluing, not because it’s required, but I figured it wouldn’t hurt to wash the used wood down. Plus it should keep the wood from sucking the moisture out of the glue too quickly, right?

I was very happy to have that big clamp in the center. It’s doing most of the work. The quick clamps are just helping to hold the ends in. The job looks good. I’m not seeing any gaps between the layers, and there was some squeeze-out. Tomorrow I’ll take it apart and see if it blows up in my face. If not, I’ll fit it to the Mark II and have a seat.

Provided this works as expected, the next step is to buy real wood a make the Mark III. Then it’s into production after I buy the wood. I haven’t done the calculations yet, but I estimate each chair will run around $35+ dollars in materials. That includes a soft cushion for the seat.

-- Ni faru ion el ligno!



6 comments so far

View Oldtool's profile

Oldtool

2375 posts in 1657 days


#1 posted 10-25-2014 10:34 PM

Nice form Dave, hope this works out for you.
I’m no expert, but I know particle board is mostly glue with a little wood chips thrown in for effect. Well, maybe not that extensive in ratio glue to wood, but the weight of it should indicate how much is non-wood. Its very hard, I’m sure your band saw blades are dull.

-- "I am a firm believer in the people. If given the truth, they can be depended upon to meet any national crisis. The point is to bring them the real facts." - Abraham Lincoln

View nomercadies's profile

nomercadies

577 posts in 1805 days


#2 posted 10-26-2014 01:58 AM

The adventure continues. Tune in tomorrow for another exciting episode of “Exploding Wood Shop” with our popular and brave Dave Rutan the Man Lam An Ator! This could be his last so … tune in or set your recorders. O-flipping-vwa.

Mia ligno estas tro mallonga kaj miaj tagoj estas tro longaj.

-- Chance Four "Not Just a Second Chance"

View Dave Rutan's profile

Dave Rutan

1430 posts in 1655 days


#3 posted 10-26-2014 11:39 AM

nomercadies, All will be happy to know that I removed the form this morning and all is well. No springback was experienced. Let’s see how it fits on the chair…

About your last line: Either you’ve been doing your homework, or it’s the only grammatically correct sentence I’ve ever seen from Google translate ;-)

-- Ni faru ion el ligno!

View nomercadies's profile

nomercadies

577 posts in 1805 days


#4 posted 10-26-2014 04:33 PM

Mi estas 68 jara. Mi laboras kiam mi volas nur. Ne estas tempo por laboro. Estas tempo por vidi la arbojn de aŭtuno. Mi dankas tempo. Estas malmulta tempo por ni. Ni devas ĝui kion ni havas.

Translated,
I’m on Interstate 68 with time on my mind but not worried cause I’ve treated mine fine. Now each mile is precious and as they appear in the rear view mirror, my friends become dearer and and my mission becomes more clear.

See the trees pass in the windows? They are going to sleep. There’s a reason the colors are so deep. The last burst of life is grand with the rest they deserve at hand.

-- Chance Four "Not Just a Second Chance"

View Dave Rutan's profile

Dave Rutan

1430 posts in 1655 days


#5 posted 10-26-2014 05:34 PM

nomercadies, The Esperanto isn’t very close to what you wrote in English.

-- Ni faru ion el ligno!

View Dave Rutan's profile

Dave Rutan

1430 posts in 1655 days


#6 posted 10-26-2014 11:41 PM

Oldtool, I’m pretty sure my table saw blade is dull as well. I’ll have to replace it. I’mm going to chuck the rest of that particle board. It’s not worth it, even though it was free. Buying plywood is cheaper than saw blades.

-- Ni faru ion el ligno!

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