This is the Morris Chair I am building.-----Well it’s time to make the corbels so I cut a tongue on some 1-1/8” thick stock. The tongue is 3/4” wide to fit snugly in the leg dado. -----Once the tongue is cut, I place the corbel blanks in a jig to trace the curved shape. -----Here the shape of the corbel has been transferred to the blanks.-----I rough cut the corbels at the bandsaw, cutting as close to the line as possible.-----Next I pattern rout the corbels to final sha...
This is how the Morris chair looks at this stage.-----I wanted to drill all the 5/8” holes for the backrest assembly before the glueup. It seems like this step would be easy to forget, so I’ll take care of it now. -----There are a lot of odds and ends to take care of before glueup, including easing edges of the parts at the router table. -----Now the side assembly can be dry fit. -----Note that the angled top side rails are 1/4” taller than the shoulders of the leg tenon...
Here is where the project is at currently.-----Before I angle the top side rails, I mark the height of the small tenon.-----Then I trim away the excess tenon at the bandsaw. -----Fitting the small tenon into the back leg mortises. -----The joint looks a little peculiar at this point because the top rails have not been angled yet. -----With the frame dry fit I can measure the height of the side slats. -----With the repeater set up on my miter saw, I cut the 10 slats to the same length. --...
Here is the project at hand, a slant arm Morris Chair. I am working off plans from the Popular Woodworking April 2011 issue, which I recommend you buy. The Author is Robert Lang. He posted a free diagram to Sketchup, but with this detailed of a project, you will want to order the back issue. My techniques differ from Robert’s methods significantly, so I will try to elaborate along the way. -----I like to start by laminating the legs for quartersawn figure on all four sides. ...
I am finally getting proficient with Google Sketchup version 8. Here is my version of a craftsman style TV console. It is halfway done at this point, however the Sketchup program was very helpful in getting the proportions pleasing to the eye. Especially shaping and sizing the corbels. I printed the corbel component, and enlarged them to scale. By simply taping the pattern on my workpiece I was easily able to cut and sand the corbels. Cheers
The rest…I had cut the parts for the ottomans and glued up (after a dry fit) – I finished the glue up – Then everything into the fume tent. I put it all in with 33% ammonia for 24 hours at about 65 degrees. When they come out they are almost black, a deep shade of gray – After putting on a coat of Arm R Seal sealer, everything turned a rich Carmel color. The final result – one of two finished and one of five in process. I also built two tables that complimented the ...
Okay, at this point, legs are glued up, rails, stretchers are cut along with all the mortices and tenons. I decided to make two chairs and ottomans to completion and then come back to the other two. The next step is to cut the stiles and tenon their ends. I planned for 3/8” tenons and cut them at a horizontal router, (although a good backer board and dado setup works as well). The glue up of each side – the tenons fit tight, so I bevel the ends even before I dry f...
…So I decided to take the plunge and make something for sale…on spec…I like the Morris chairs so that’s what I went with. Always a timeless classic, clean lines, and fun to build! I brought forth the Visa and bought $3000 worth of white oak (this is my first venture into the “professional” arena). I planned on building 4 chairs and ottomans. I’m not going to quit my day job, but thought I’d give it whirl on the side…The first thing I can tell you is everything that everyone has been sayi...
Ok…..Time to add this to the projects page. She’s finally done, no more sanding (I don’t think I have any fingerprints left), the finish actually looks good, and the cushions came out great. This was a looooonnnng project. Thanks to all my fellow LJ’s out there for your encouragement Suzanne still has a different material to make the final cushion covers with. We bought two because the material was ridiculously cheap. She made the first one out of the material...
Wow…..is foam rubber expensive. We picked up the foam last week but have been waiting for the zippers to arrive (had to order online). The seat is 5” of high density foam wraped in 1” of low density foam and then batting. The back is just 4” of low density foam wrapped in batting. They feel pretty comfortable. The seat is a little stiff but should break in quickly with me on it. Hopefully Suzanne will get the cushions done this week. We bought two materials. Niether...
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