|Project by noahhl||posted 05-27-2013 07:05 AM||1806 views||8 times favorited||19 comments|
This is a set of twelve dining room chairs based on the Fine Woodworking ””Build an Elegant Dining Chair video workshop series and plans by Matthew Teague.
A few (low quality) pictures of the construction process:
Starting with full size drawings from the side and at seat level:
The first of two prototypes I built out of scrap pine before committing to a big lumber order:
Raw stock getting ready to be machined. Chairs are entirely made from hard maple:
I built a crude horizontal slot mortiser out of drawer slides to try to cut the numerous angled mortises. It ended up being too difficult to secure the workpiece, so I switched to using my MortisePal and a set of wedges:
A stack of seat rails partway through the mortising. In all, more than 200 mortises were cut for the set of chairs:
Front leg and seat rail combos being glued up:
A stack of rough back legs waiting to be shaped on the router table:
Shaping finished and ready for mortising:
I don’t have any pictures of shaping the backs, but it was certainly the hardest part. I didn’t do a very good job at cutting them out on the bandsaw, so there was a lot of shaping to be done with a variety of sanders and spokeshaves.
Band clamps and wedges worked well to bring everything tight:
More band clamps to bring the whole chair together:
The upholstery was surprisingly easy. Just cut, glue, pull, and staple. Close to 5000 staples used in all:
An improvised turntable from a spare seat blank worked well for finishing. I decided to spray finish with one thin coat of shellac and three coats of General Finishes Endurovar.
Hope you enjoyed! This was by far the most ambitious project I’ve taken on, and while it didn’t turn out perfectly, at least they don’t fall apart when you sit on them!