The crest and lower back rail were to be from 1 7/8” stock. As I didn’t
want to shell out for 8/4 stock I ran 2 pieces of 4/4 through the planer
to get a nice smooth surface then glued them up. The jury is still out
on whether this was a good idea or not. After trimming the stock to
it’s finished size I laid out the curves and laid out the tenons. As I
said before, laying out the larger chairs was a bit challenging.
I cut the tenons first. Snuggling up to the fence ensures everything
will line up.
And again I used this guy to remove the waste.
At this point I moved over to the back splats. After ripping 24 pcs 5/8
X 1” I cleaned up the saw marks with the scraper.
I set up a dado set just under the 1/2” the tenons are supposed to be as
I didn’t want to chew up my fence face.
I ripped my Walnut pcs to 1 1/2” instead of 1 1/4. There is a 2° bevel on the edge
and I’d rather start off big and move in. So I set up the Wixey again and cut my strips.
Ya gotta pay attention to orientation again. 2° isn’t much so be sure your work piece is angled correctly when you flip it. About ready to head to the router table.
After a bit of searching I found a drawing for a DIY router insert for my T/S. It works pretty slick.
My Walnut strips are a touch over 5/16 thick, so I had to make 2 passes with the 1/4” bit.
Once the groove was cut I had to square off the ends with a 1/4” chisel.
Now for the crummy job, cutting the mortises for the back splats.
Not having a dedicated mortiser I had to do all 48 by hand. I started by laying the holes out with a template.
Then drilling a 3/8” hole on the drill press. The tenon is 1/2” long, so I went just a bit deeper.
Then the fun part. 3/8 on each end x 1/2” long.
That pretty much took the day. Next up is fit and finish. The band saw left
lumps and bumps that needed to come off. I hit them briefly with the belt sander then I used a half round file and a scraper to finish each one.
Getting close to the end know. I used the paper template that came with the drawings to
lay out the curve on the crest rail.
I was concerned about tear out on the band saw when I cut the curves so I taped
I had cut out from the face of the crest rails back in place. This also gave me a flat
surface to work with.
I ripped some Walnut down to 2” wide by 3/16 thick. These will dress out the top
of the crest rails.
After cutting the curves I had to smooth out the ruff surfaces again to receive the Walnut strips.
I used the left over pieces from the tops of the crest rails to sandwich the Walnut
for the glue up.
Outta the clamps and time to trim the Walnut. A sharp chisel and a spoke shave
serve the best.
The final assembly X 6.
Then the whole assembly is taken apart for final sanding.
I will put a lite clamp on these assemblies and use them for laying out the locations
for the mortises in the back legs.
I will not glue these pieces up ‘till the mortises in the legs are complete.
Thanks fer looking. Untill next time.