Time for some actual hand work.
When I traced the pattern on the front legs I always used the top of the leg as my reference. I made a little spacer that I rested the template against to space it from the end. That way every leg would be the same. I left the parts long to I could cut off the part of the legs with the marks from the spur drive and center that I used to hold it in the ornamental mill and lathe.
I clamped a square piece of wood, taller than my leg and long enough to clamp to my fence. Then I trimmed the end square. This edge serves two purposes. First it gives me a nice straight edge to line up the mark I made on the legs. This will tell me exactly where the saw will cut it.
Secondly it makes sure that I get a nice clean cut on the leg with no splintered edge.
Here you can see the leg with the line about 1/4” from the end of the spacer block. It’s as simple as lining up the line with the end of the block and cut.
I will cut the bottom of the legs to length as one of the last operations. This way I will be certain the chair will sit flat and not rock.
Now it’s time for matching up parts. With this much wood you will get variations in color and texture. At this point I match up the front legs, the front and side aprons for color and texture. Once everything is matched up every part will be numbered.
I have 16 legs so I give them numbers from 1 to 16. For the front and side apron that fits the leg I mark tenon with the same number. It really makes it a no brainer after doing that. Tenon #4 goes into mortise on leg #4. The front apron for example will have a #1 and one end and a #2 on the other. These fit legs #1 and #2. I don’t have to re-think everything every time I take it apart.
At this point I use just use a chisel to clean up everything and make things fit exactly like I want them to. Basically every tenon is custom fit to a particular mortise.
Other than the setting how tight the fit was, I made sure that the top of the aprons fit perfectly flush to the top of the legs. I left the tenons a little oversized just for this reason.
Here you can see the fit as well as all the other assemblies in the background.
At this point all the work is going into the front part of the chair.
Next is adding the knee blocks.
-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX