Right now the chairs are kind of plain with the straight, square top of the back. I plan to add something to change that.
First I start out with that material I was gluing up a post or two ago. (see I was actually thinking ahead!)
The material I used must have been on the top of the pallet because it had very dark staining. Some places as deep as about 1/4”.
The material I need for this step is thicker than any I had, so what I did was to glue up the two pieces with the stained faces facing out. Then I just cut off both the faces and ended up with some nice clean wood. So I killed two birds with one stone. Used some nasty stained wood and made some extra thick stock.
I cut it into strips. Since I only had a few pieces to make I didn’t bother with the dado blade. I just started with a cut in the middle and ran both sides of the part against the fence to center the dado. I think it tool a total of 4 passes moving the fence a little farther away every time until I ended up with a nice perfectly centered dado.
While I did that I also did the top rail for the back of the chair. You can see it on the right.
Then I cut all the parts to length and at the correct angles.
Then I made a little fixture for gluing the parts up. It was real quick to make with some glue and a brad nailer. The gaps and holes are for the glue squeeze out. Those extra little blocks are to give me something to clamp against. You’ll see in the last picture. I also clamped it to the table to make sure that it was nice and flat.
To make sure dados the lined up I made some little triangles the fit the dado just perfectly. I notched the point of the triangles so that they wouldn’t get any glue on them. Here is a mock-up for the gluing.
Here you can see the parts all glued and clamped. You can see what those little block are for. The clamp in the middle is just to hold the center part in place while the clamps on the ends are applying the pressure.
Since I have only one fixture and 8 parts to glue up, I decided to do some finish sanding while the parts dried.
(have I mentioned that I hate sanding?)
I wet the legs to raise the grain and sanded them once dry. Then I cut them to final length, so minus the finish and assemble they are finally done.
Next time I’ll show you the last piece for the top of the chair.
-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX