Looking at all my other projects, you all probably know that I like the look and working with mahogany. So It should not come as a surprise to anyone what I will be making this project from.
Making the chairs will be something new for me. I have never made one before, let alone 6-8 of them.
After studying my current chairs and plans for others, it shouldn’t be too hard.
Making so many of something as complex as a chair I will be making templates for everything.
I want all the pieces to be as close as I can make them to each other. This is where templates and jigs come in to play.
Here’s what I made for the back leg.

Since I am throwing it away after I am done with it, I didn’t put too much time and effort into it.
I started on the left side and did one side and the ends. Then I used to other side for the opposite side of the leg. I just moved the clamps when I switched sides.
You can see a leg in the jig with the template resting on top of it. You will notice some blocks glued to the top of the right side. These are to line up the previously cut side with the template. The part and the template both butt against them.
The template is 1/2” MDF which is clamped to the top of the leg blank. Then it’s cut using a bearing guided router bit.
Here’s the bit and a little bit of mess:

And some more of the mess. Sitting on the floor is a test piece I made the check out the curve of the back. It was very comfortable.

Here are all the legs I made. Enough for 8 chairs. I really only need 6 but I have two extra in case I screw something up along the way. If not I get two extra chairs.

Next I will start on the front cabriole legs. They will be the most time consuming part of the entire project.
I started this blog after having already made the back legs so it will be a little while before I get back for the next installment.
-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

















22 comments so far
TopamaxSurvivor
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13192 posts in 1843 days
#1 posted 763 days ago
Gary, I have never made one either, but would not hesitate if I decide i wanted to, so you should be able to crank them out in your sleep ;-)
-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence Wake Up America!! Please read; http://www.commondreams.org/view/2009/01/26-0
Dennis Zongker
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2177 posts in 1759 days
#2 posted 763 days ago
Hi Gary,
Looks like your going to have some fun on this one. It’s nice to see you back into the big pieces again. You are an excellent craftsman & I’m looking forward to seeing the progress.
-- Dennis Zongker
JuniorJoiner
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441 posts in 1608 days
#3 posted 763 days ago
I’m certain your chairs will impress, seeing your the craftsman.
Look forward to more, i’m glad your finding the time
-- Junior -Quality is never an accident-it is the reward for the effort involved.
shipwright
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3381 posts in 965 days
#4 posted 763 days ago
Coming along nicely Gary. Nice to see someone else makes as much mess as I do. I like your ideas about your chair backs. Very few dining sets have comfortable seat backs with lumbar support. These are looking just right. I’ll be following.
-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/
Joe Lyddon
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6390 posts in 2220 days
#5 posted 763 days ago
Looks like a nice bunch of Legs!
Have you made a prototype or just going at what you think is it?
-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"
Lee A. Jesberger
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6494 posts in 2147 days
#6 posted 763 days ago
Hi Gary;
This is going to be fun to watch.
You’re off to a good start.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Todd A. Clippinger
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8654 posts in 2267 days
#7 posted 763 days ago
Look forward to seeing these come together.
-- Todd A. Clippinger, Montana, http://americancraftsmanworkshop.com
patron
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12051 posts in 1508 days
#8 posted 763 days ago
good going gary
simple jigs work just as well as art ones
i know you will enjoy the various challenges as i did

when i made 8 chairs too
-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle
BertFlores58
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1529 posts in 1090 days
#9 posted 763 days ago
Good start. Looking ahead on the next step.
-- Bert
tenontim
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2129 posts in 1912 days
#10 posted 763 days ago
That’s the trick. Have a pattern so they all come out the same. The hardest part of making a set of chairs comes when it’s time to sand all of those parts. Keep us posted.
-- Tim-- http://www.tmuli.com
Karson
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34369 posts in 2568 days
#11 posted 763 days ago
Gary: I love pattern cutting. Nice use of the jigs to make them. Is that a solid carbide spiral with a bearing?
-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †
alan coon
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110 posts in 1880 days
#12 posted 763 days ago
i made 6 chairs out of mesq. Then made 2 more,but kept the hard pat’s. Just in case. Yours are going to look great,as all your other things have in the past. good start!! My chairs were a first time try also.
-- Al, South E. Az., But it's a dry heat.
lightweightladylefty
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2054 posts in 1880 days
#13 posted 763 days ago
Gary,
This should be good instruction for those of us who haven’t yet made a chair. We’ll be following along.
L/W
-- Jesus is the ONLY reason for ANY season.
GaryK
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10263 posts in 2156 days
#14 posted 763 days ago
Joe – The only prototype I felt that I needed was for the back. The rest is standard dimensions. You can see the prototype for the back in the lower right part of the third picture.
Karson – Yea that’s a solid carbide bit with a bearing. It’s one of those compression bit I blogged about earlier.
I got it from Woodcraft with the winnings from the last contest. If I would have known how good it worked I would have spent the $100 a long time ago.
-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX
TopamaxSurvivor
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13192 posts in 1843 days
#15 posted 763 days ago
Gary, i just looked through your blogs and reviews, i didn’t see anything tilted carbide bit. Where did you rite about it? thx ;-)
-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence Wake Up America!! Please read; http://www.commondreams.org/view/2009/01/26-0
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