Getting close to the end!
Here you can see that I added all the corner supports. They were basically straightforward. I cut one at 45 degrees, flipped the board over and cut another and so on. Then I set the miter gauge to 8 degrees and trimmed one side to match the angle of the sides. Then did the same at 8 degrees on the other side of zero for the other end.
Then to the drill press with a couple of brad point bits. First a 5/16” to create a counter bore and then a 3/16” for the through hole. I wanted a flat bottom for the pan head screws I attached them with. I didn’t want a flat head screw since that would probably split the corner blocks.
I used hard maple. I like the way the end grain cuts to so smooth a finish, and their strength.
I probably could have gotten away with just one support in each corner, but I want these to last for years to come. I glued and screwed each one with 2 screws.
Now on to the seat bottoms. To make the first one I just set it in place and the marked it to notch the 2 back corners. Then after I cut them, I put them back in place and traced the final shape using the sides of the chair as a guide.
Note that they were all cut to length and width first on the table saw.
Once I got the first one the way I wanted it, I held it against each of the others in turn and traced lines to cut to. I just cut them on the bandsaw since they aren’t critical.
Then I placed my first one in place again and traced the inside.
Then I drew a line diagonally. This showed me where I needed to drill the hole in each corner. These are the holes I will use to attach the seats to the chair. I use a small little drill bit to drill all the holes. I will use this hole as a pilot hole for the bigger holes I will drill later.
Then I use that first part as a template for all the holes in the other seats as well as the corner blocks in the chairs. This will assure that all the seats will be able to fit any chair. All interchangeable.
Here you can see I am drilling all the holes in the chair corner blocks. These holes will eventually be opened up to 5/16”.
Then I also open up all the holes in the seats to 5/16” also to accept the T-nuts. They are for 1/4-20 screws.
Don’t even think about going to a big box store to buy them. I bought 100 from McMaster-Carr for about $7.50. Even with shipping they would cost about the same, but you end with a lot extra.
Here you can see them all complete! One step closer to being done!
Next I will show you how I did the back.
Can anyone guess how I will do it?
Remember it will have to conform to the back, be strong enough and be able to be upholstered.
-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX