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 fit. It’s a little tricky getting all the stiles in, but it gets easier, put all in the wide bottom piece first with just a spot of glue so they won’t rattle later (I made sure all vertical grain was facing out), then hold the bottom piece on the bench and resting against your waist, set the top of the arm at an angle and roll on to the stile tenons.
When the sides were glued up, I glued up the bottom part of the chair and added the arm and seat supports.
With the bottom of the chair complete, I turned my attention to the backs – I had already cut the parts and dry-fitted (I do a lot of dry fitting)
At this point I’m ready for the arms. I use an old trick to cut the arms on an angle from a glued up board and block. You cut the top and bottom of the block on a 9 ½ degree angle (same as the rear leg tenon and arm slope).
Next I laid out for the leg tenons and routed the bottom of the arm to fit over the stretcher about a ¼”. I rarely am able to cut a through mortise cleanly on these arms. I use glued up buttons to cover the leg tenons. A dirty trick, but it looks much better than my through mortises. I glue up the button stock in the same way as the legs so that all four quarters show through – they really look end up looking great and experience has taught me that the first thing people do when they sit in these chairs is eww and ahh over the buttons.
So the next thing is to pin all the joints with black walnut dowels. I listened to what Karson had to say about the Veritas Dowel maker and bought one – what a great tool! I sink the hole using a “lipped tip” Brad Point bit for a clean hole with no tear out, drive in the dowel, flush cut and sand.
One last dry fit and onto the ottomans –
To be continued…
-- The Gnarly Wood Shoppe
8 comments so far
Drew1House
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421 posts in 538 days
posted 331 days ago
Awesome… looks like they are really coming along. I will favorite this one and try one someday. (Wife does not like this style so it will be for a gift for somebody someday…
Drew
-- Drew, Pleasant Grove, Utah
Thos. Angle
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3244 posts in 413 days
posted 331 days ago
Quite a project you’ve got going there. It looks like it is turning out very good. I like the buttons. They do add a lot of class and yes the customers will ooh and aah over them and not see those things you worked your butt off on. There just ain’‘t no justice.
Tom
-- Thos. Angle, Owyhee Design, Oregon
Bob Babcock
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1811 posts in 537 days
posted 330 days ago
Awesome…you are making things look easy on four that took me a long time on just one.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
Lee A. Jesberger
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2596 posts in 430 days
posted 330 days ago
Hi Schroeder;
Very nice work. It’s quite an undertaking you have going there, but it looks like you’re approaching it in a production line fashion. Well done.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
WayneC
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5689 posts in 548 days
posted 330 days ago
Great looking chairs. Lots to learn in this post.
-- We must guard our enthusiasm as we would our life - James Krenov
Dorje
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1738 posts in 447 days
posted 330 days ago
Looking rock solid – this is some serious work you’ve put into these chairs! Impressive to say the least.
-- Dorje (pronounced "door-jay"), Seattle, WA
schroeder
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462 posts in 576 days
posted 330 days ago
Thanks all very much all, its a big project for me, but, man I am having fun! obsessive/compulsive woodworking! (a lot of times I wake up at 2:00 – 3:00 and go to the shop for a few hours and get back home before my little hen even wakes up – thats just sad I know, but at least I’m not killing as much family time ;)
-- The Gnarly Wood Shoppe
shaun
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360 posts in 356 days
posted 329 days ago
Dorje and Tom are taking the words right out of my mouth, that’s some serious work going into these chairs and I often wonder if the customers can appreciate what goes into projects like this. I suppose all that realy maters to them is that they are happy with the end product, true appreciation of the time and craftmanship will come from us, and that you have!
-- I've cut that board three times and it's still too short!