Client is pleased.
The new stretcher is attached with three pocket screws per end. Each one was custom fit so it slid in without any undue stress on the old stretcher joint, all of which were reglued with epoxy.
The screw pockets were daubed with stain. It is possible to note them from a certain angle, but you have to be short in the torso or slumped down in your chair in order to do that. All in all, a successful repair.
One certain learning: in epoxying the M&T joints and the armrest-leg joint, I inserted ample epoxy and squoze the joint closed slowly, making sure there was no glue starvation. I promptly wiped off the squeezeout. After the mandatory 24 hours cure time, the glue was not always flush with the surfaces—it appeared to have receded. On one severely broken back leg joint, there was some wood missing and I filled that area with epoxy, which cured concave. I am wondering if this brand of epoxy has some shrinkage. I haven’t experienced it before, but this is a new brand to me.
Also, the masking tape on the joints left residue only on the areas where there was epoxy on top. I wondered if there were some heat transfer there that cause the deposit of the material. It did not come off easily. The best solution was rubbing alcohol which cut the residue without disturbing the lacquer finish on the chairs.
On some chairs the new stretcher color did not match the seat rail, but on others it did—I noted that there was a wide range of colors on the various chair parts. I don’t know if the parts were prestained pre assembly from differing batches of stain or if the material wasn’t stirred as each chair was stained.
-- "...in his brain, which is as dry as the remainder biscuit after a voyage, he hath strange places cramm'd with observation, the which he vents in mangled forms." --Shakespeare, "As You Like It"