Seems every week there is a real life setback, this week was no exception with my wife succumbing to the head cold I had two weeks ago. She is better now.
On a shop note I have another commissioned job that is due the same time as this, so instead of having a nice 6 week buffer on the chair, I now have 6 weeks to finish the chair and complete the other project, time to kick it into high gear.
So this entry concerns the front and back legs, their shaping and gluing to the seat.
Started out today by sanding the bottom and top of the seat through to 500. Someone questioned the sanding technique last week. I came up with some more explanation. The chair is so complex when assembled that to try and sand the completed chair from 220 to 500 would be a real PIA. So I sand every piece as much as I can before assembly. There will be some re-shaping and re-sanding as assembly progresses, but those areas are limited.
Due to the weird shape of the front and back legs, they cannot go through a table mounted router easily. So a riser pyramid is built. I bought some extra inserts for my router plate and have a couple different sized pyramids that I can easily pop in and out of the router plate:
The front legs are then run through the router to round over all corners, followed by sanding to get rid of the band-saw lines and smooth it all out. Then set them aside.
Certain corners are then run through the same round-over router jig as the front legs. Then the legs are sanded to remove band-saw lines, smooth out the transitions and cleaned up. After the rough sanding I then drill the head-rest screw holes. First a forstner bit to create a pocket for the wood plug to occupy, then the through hole. You want these to be straight so clamping in a vice on the drill press is pretty essential:
After this sits over night I will finish shaping the front leg joints and sand the seat and legs flush to each other. The arms will be mounted after that. After that I will start shaping the back braces for when the head rest gets finished.
-- Rich, anybody want a peanut?