methods of work #20: Chair mockup seat/front leg unit

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Blog entry by Loren posted 10-06-2013 11:54 PM 1422 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 19: Chair prototype #2 - all the tricky stuff is done. Part 20 of methods of work series Part 21: Steam bending recurve - FAIL »

In working on this bentwood chair design I didn’t want to glue the
frame and front legs together but I wanted to experiment with
some different shapes for the back legs.

I glued up a 2” thick chair seat out of 1/4”’ ply on the outside with
2×4 scrap inside. I just made one plywood side accurate to the
shape and used that as a pattern after the other layers were
glued up. I used an overarm router but a flush trim bit or pattern
bit would work nearly as well. I notched out the front corners
3/4” on the table saw and made up some 1.25” x 17” pine front
legs and glued those on. Before I did that I marked the position
for the back legs and drilled/sawed out rectangular holes for

2 comments so far

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36 posts in 1753 days

#1 posted 10-07-2013 12:33 AM

Nice template.

I always learn something new when I read your posts. The other day I found out about vertical panel saws, and today I found out about overarm routers. I wonder what other machines I dont know about.


View Loren's profile (online now)


10476 posts in 3669 days

#2 posted 10-07-2013 12:42 AM

You can see the router here:

It uses a guide pin in the table the same diameter as the
cutter above. It can be set up with crazy templates
to make all sorts of weird cuts like those used in routing
out electric guitar bodies and it can do some types of
production mortising and drilling, but in general I just
use it for trimming curved parts to a template.

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