|Project by Odiferous||posted 05-19-2013 08:52 PM||2327 views||2 times favorited||1 comment|
I embarked on this project almost entirely as a skill builder—though we have no other outdoor seating at the moment, so it’ll be nice to have around. I started from rough cedar 2×4s and fired up the jointer to try to make usable lumber. I ended up taking the boards down to 1 1/4” thick, and learned why you don’t thickness material on a jointer. Also, cutting the boards roughly in half after making the rip cuts made it much easier to go back and clean up the sawed faces on the jointer.
I ran a 1/4” round-over on every edge, which started some nasty slivers splitting off the edges. I didn’t have wood to replace those pieces, so I just sliced them off and turned that bit to the outside of the chair, but they’re pretty unsightly. Sanding that many faces was not terribly pleasant, but at least cedar sands easily.
I strung all the sticks up between garage door tracks using the 1/8” cable that eventually went into the chair, and wiped them down with thinned spar urethane. I still think hanging them all by the cable for finishing was a good idea, but the execution lacked finesse—5 coats of wiping varnish and a couple of steel wool rub-downs on 25 dancing dangling sticks while standing on a ladder was…...interesting.
The only real deviation from the plan I felt was necessary was the addition of a small bit of heat shrink at the end of each cable, just to keep them from fraying. Those little wires can be nasty. I doubt it’ll hold up to the UV all that long, but we’ll see.
This project sure made me wish I had a miter saw or a RAS. I don’t think I’ll make another without rigging up some way to use a stop block for the cutoffs.