|Project by JoshLawson||posted 04-30-2012 01:33 AM||2808 views||24 times favorited||16 comments|
I finally finished this set of 8 dining chairs after having started them more than a year and a half ago. Sure I’ve done several projects in the middle, but it sure is good to finally have these finished and out of the shop.
I used traditional wedged mortise and tenon joints for all the lower structure and I additionally pinned a few of the mortise and tenon joints to provide better strength (as well as to match some bar stools I made earlier). The back slats were taken from a set of plans for a Maloof style rocker by Hal Taylor, excellent lumbar support!
The seats were all rough carved using a router and a custom router jig, then I used the more common method using an angle grinder with a tungsten carbide spur bit and sandpaper to finish it up. The router jig helped make all the seats very similar looking.
One other interesting thing I did was for the feet on the chair. I just put in the hard maple floor the previous week, so to help avoid scratches I added Delrin (a specific plastic, commonly used for furniture feet) pads to the bottom. I looked at various sources for these (Lee Valley, Rockler, etc) but found them all to be overpriced. So instead I went online to my favorite industrial supply company (McMaster – they are absolutely the best if you haven’t used them yet) and ordered five feet of Delrin 1.25” diameter round stock. I cut the round stock down to 3/8 inch disks using my chop saw (make sure to use a zero clearance insert… otherwise it gets ugly), sanded down the front face, drilled and countersunk a hole in the center for the attachment screw, and rounded the bottom edges… and voila cheap scratch free feet! I also countersunk the Delrin pads into the bottom of the legs, which provided an opportune time to final tune the leveling so the chairs won’t rock. If you drill the hole too deep, just add a washer underneath, it’s out of sight and secure.
-- Josh Lawson - Ankeny, Iowa