Summer has flown by. I found a little time here and there to work on the stools. It never seemed like much, but when I look at the result I can see significant progress. I’ll show how I spent my summer (when I was in the shop).
Preliminary Leg Shaping
Several of the leg pieces shifted shape during the rough cut process. The final shape of the back legs requires some material removal. I decided to shape the side that removed material from the center of the leg. If the wood shifted I could adjust the straight side. By leaving one side straight I still have a reference edge for locating the mortises.
Sure enough after a few days, about a third of the legs shifted somewhat. I set up a straight edge and ran the router along it to get a true edge back. The picture is not very good – you are supposed to see the offset in the mahogany.
I then was able to use the shape template and route the final shape on the legs.
Mortise Front Legs
I then waded into a seemingly endless stream of mortises and tenons. First up – the legs. I measured and drew out the location of each of the mortises. I finally got to put to use the mortiser I bought just for this project.
I followed up by cleaning up the mortise with a mortising chisel. Most of the work was cleaning out the bottom of the mortises.
After several days, I had a set of mortised front legs.
Tenon Rails – Round 1
I then focused on tenons for the rails to fit the new mortises. Six rail parts added up to 8 tenons (on each of 6 stools). Once again I need to keep close track of the parts to preserve all my effort to match the grain and colors. I mentioned before that I use a dot to indicate the top right front corner of each piece.
48 tenons later, I have the start of something that looks like it might become a stool for the kitchen.
Mortise Back Legs
Next up is all the mortises on the back legs.
More Rail Tenons
The angled tenons allowed me to create some interesting set ups for my tenoning jig. This one is set up so I can cut both sides.
Here is another set up.
After another set of tenons, I have six stools with four legs.
Mortise and Tenon Accent Posts
Next up is the 3 posts on each side. Mortises were cut and indexed with spacing blocks.
Here is a fit up with the accent posts installed. The bottom rails are all in place as well. Notice how the pile of parts on the bench is getting smaller?
Cutting Tenons on Curved Rails
I used the fixture for gluing the curved parts to hold the curved rails for cutting tenons. Some stop blocks and a cross cut sled worked great!
I would use shims to sneak up on the final tenon width.
Final Fit Up
After another assembly of the pieces you are caught up. The pile of parts on the bench is down to the seat back slats. They are up next!
Current time log:
Cutting rough stock: 2 hrs
> Cutting to width and thickness: 4 hrs 20 min
> Cut to final length: 3 hrs 30 min
> Shaping: 5 hrs 50 min
> Mortises: 10 hrs 35 min
Seat Back and Back Rest
> Cutting thin stock for laminations: 3 hrs 35 min
> Prepping laminations: 8 hrs 40 min
> Glue up Laminations: 3 hr 50 min
> Trim Laminated Parts: 2 hr 25 min
> Tenon: 5 hr 10 min
> Cutting thin stock for laminations: 1 hr 55 min
> Prepping laminations: 3 hrs
> Glue up Laminations: 6 hrs 5 min
> Trim Laminated Parts: 10 min
Lower rail parts
> Cut to width and thickness: 10 hrs
> Cut to length: 1 hr 30 min
> Mortise: 3 hr 50 min
> Tenon: 23 hrs 30 min
Total so far: 99 hrs 55 min (16+ hrs per stool)
-- Steve - Impatience is Expensive