Sorry for the delay. But I have been crazy resetting the shop, installing my new dust collector, and getting my heat straightened out.
I had a bit of a tragedy in my chair as you can see in this pic. The seat split. I am trying to figure out the best repair solution so that it is strong and the crack does not continue.

Anyhow, the following photos show my rough sculpting and joinery. I still have at least 40 hours of work left as I need to finish the back slats and chair back, install and sculpt the rails, and finish sand everything.
Enjoy the pics.



-- making sawdust....






















12 comments so far
snowdog
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808 posts in 876 days
posted 328 days ago
Wow, That looks like so much work. Some day I hope to have say “I made a rocking chair” but that is off in my future (I hope).
-- "so much to learn and so little time"..
Tony
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811 posts in 924 days
posted 328 days ago
Try a butterfly insert below (strength) and just fill the top of the seat best you can, that is the best I can think of at the moment.
You could also reduce the size of the tennon, by a few thou, to reduce the compression stress after the seat is repaired.
The chair is looking good, something I have always wanted to make, but just never got around too.
-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)
Harold
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312 posts in 741 days
posted 328 days ago
like tony mentioned, butterfly(s) if you were to use a similar wood and fill the crack I would consider it a repair…but if you were to use a contrasting wood and dark filler in the crack I would notice this as a beautiful design feature, complimenting the natural beauty of a living work of art. perhaps the butterfly’s could gradually get smaller as they traveled further down the crack..perhaps even add a couple in the head rest..to continue this theme…subtle..but it would definitely transform a familiar design into a piece that is much more personal…and relevant…..who among us here don’t have a few faded scars….this is our story.
-- If knowledge is not shared, it is forgotten.
mranum
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94 posts in 309 days
posted 303 days ago
Sure looked like a wonderful educational opportunity though. Someday, hopefully I will have the opportunity to try one of these chairs. They are beautiful.
Now that you have gone this far with it, whats the one thing in a tool that you simply have to have?
-- Just remember,it was a lone amatuer that built the ark, and a team of experts built the Titanic.
motthunter
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2079 posts in 692 days
posted 303 days ago
have to have a horizontal borer… seems like a silly thing to say, but it made the joinery and doweling so much easier.
-- making sawdust....
Tony
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811 posts in 924 days
posted 303 days ago
A “horizontal borer” is that not another name for a “Brace & Bit” or “Hand Drill”?
-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)
motthunter
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2079 posts in 692 days
posted 303 days ago
nope.. I have a super shop.. this is kind a bigger and better version of the shopsmith and I use it as a lathe, large disc sander and horizontal boring machine. I would never use it as a table saw… not safe as I see it.. But as these items and even a super strong drill press, this tool is magic.
Some day I will have to post some photos and show how versatile it is. I got turned onto this machine when I used one at Bill Kappel’s shop in Utah. After I used it there, I found one on Ebay and had to buy it.
-- making sawdust....
mranum
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94 posts in 309 days
posted 302 days ago
Hmmmm guess its a good thing I just got done redoing my old shopsmith then.
-- Just remember,it was a lone amatuer that built the ark, and a team of experts built the Titanic.
motthunter
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2079 posts in 692 days
posted 302 days ago
i think so.. they are good for many tasks.. just not all
-- making sawdust....
Karson
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25792 posts in 1294 days
posted 302 days ago
A great looking chair. have you decided on the repair techniques. I also think that a series of butterflies would look great. That way you don’t have to hide the crack.
By the way I have a horizontal router table and they come in very handy for mortise and tenon work.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
motthunter
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2079 posts in 692 days
posted 302 days ago
Carson,
I my daughter is a nurse so she got me a long, thin needle syringe and I injected the crack with Gorilla glue then clamped it. You can’t even see the crack now. It worked like a dream.
This was a suggestion both from Bill Kappel and the owner of the local Woodcraft store. They both know far more than me and I owe them my gratitude for their help.
-- making sawdust....
ScaryDAve
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14 posts in 446 days
posted 296 days ago
OK There is a project which is far, far outside my the boundaries of my patience heheheh.
That’s some seriously great work you got goin on there.
-- If at first you don't succeed, slam it on the ground, kick it across the shop, blast it with a shotgun, tell the kids to cut it up for firewood, turn up the music an try try again.