|Project by Luddite||posted 03-07-2015 04:03 PM||1766 views||4 times favorited||7 comments|
After several years of pestering me, I finally agreed to build two Morris Chairs for a client.
The build would be from Cherry with some mesquite highlights, similar to other pieces made for her. Fishing around for my old plans I picked up the Woodsmith chair design and decided to go with that and of course make changes as needed. My initial trepidations were:
- Actually being able to do some of the work with what tools I had. In the past MC build I’d used a larger shops tools.
- Making the bent arm. More on that later.
- Making curved back slats.
- Did I really want to do this. I’d built two others of mesquite 10 years prior and it nearly killed me.
Regardless of my Fear & Loathing I started.
- The design wanted a 9.5 degree slant from front leg too rear. I decided to use my compound cut off saw.
Setting a 9.5 degree angle on the horizontal I trimmed ends on four posts (two chairs). Set the ‘set screw’ to a 3/8 inch depth and setting the angle I then cut the first side of the top tenon on each piece. Reversing the settings and stop block I did the other sides. Resetting to 90 degrees I made two cuts at the tenon base and using my band saw trimmed off the rest of the post tenon.
- It wasn’t pretty but worked.
- Milled the supporting rails and slats.
- Assembled the base units and applied first coating of oil.
Due to machine limitations I was unable to do the classic bent arm which was laminating an extra end to the arm and cutting with a band saw. After posting this problem and my suggested solution I gained much needed advise on how to continue:
- Make an angled cut one half of desired angle of descent where your arm will bend.
- Make a reciprocating cut on the other piece.
When joined back they will equal the desired angle.
- Using a tenon jig make a deep through dado on the ends of each piece.
As the angles are the same for both pieces the same set up could be used for all pieces.
- Using again the tenon jig, prepare a floating slat with grain in same direction as the arm.
- Prepare the underside dado’s and fit to test.
Base units were assembled with arms in place. Added value features for the client included:
- Inlay of turquoise and other elements.
- A meteorite fragment from Argentina.
The backs were prepared, assembled, tenon caps and peg holes made from mesquite and installed and the chair was tested.
——————————-end of project
Final work was applying Watcos natural oil. Four rubbings with sanding to 800 grit.
-- T Loftus -- Just on the edge of common sense