He now has the legs and the upper and lower stretchers done with the exception of shaping the top of the back legs. That can’t be done until we fit the crest rail.
We worked on it for 12 hrs on Saturday and he cut the indent in the feet and shaped the tappers. To cut the tappers we had to make three different jigs and six different setups for all the different shapes.
I had see in a book how to shape the tappers with a stationary sander but that was with square legs and on his the front legs are parallelograms and the back are trapezoid. I showed him how to do it with a rasp on the prototype. I was a little concerned but he has to do all the work on the final chair to enter it in the competition. After his first one looked better than mine I stopped worrying.
We still have a lot of work but it is starting to take shape. He has tracked his time every day from the start of the prototype and he is now at 85 ½ hrs.
The last thing that really scares me is the back splat. I have no idea how to size it from all the pictures I have seen other than just keep cutting until it looks right.
We normal work each night starting at about 5:30 or 6:00 and we live stream on http://www.ustream.tv/channel/plane-old-wood so his brother and sister can watch from college. They like to give him little pointers on skype while he is working.
-- Jeff Waggoner, https://www.facebook.com/PlaneOldWood/