Shaping and sanding is pretty easy to figure out, so I’ll just share a few of the techniques I used on this project.
The back legs still needed to be cut to final shape on one remaining side. The template was clamped onto each leg.
The shape is traced onto the leg.
Cut on the bandsaw with about 1/16” left.
A router with a guide bearing and straight bit made the first pass using the template.
Even with multiple passes, I still had an occasional blow out.
Repairs involved gluing pieces back in place and then routing very carefully. After this one, I used the disc sander to get very close to the line before using the router.
Nearly every exposed edge has a radius routed on it. Radii of 1/16, 1/8, 1/4 and 3/8 were used. Here is example of the bottom of the front leg. I sand the surfaces to 120 grit before I add the roundover routing. The smooth surface helps create a cleaner roundover.
The larger radii caused me some concern. I set up the fence on my router table with a spacer strip.
This allowed me to make a first pass with a partial depth cut.
Then I flipped up the spacer strip and made a full depth cut. If you look closely, you’ll see that the bit is not flush to the fence. This way I could get the first and second passes to be the depths I wanted.
The next thing to cover is the sanding. I have put in LOTS of hours sanding. Not that I mind. I kind of enjoy feeling how each grit makes the part more smooth. The hours are from the fact this project has lots of parts.
And those are just a few of the parts. Remember there are 6 of these!
I do my sanding by hand. I use a block for the flat surfaces.
A piece of an old mouse pad for the radiused edges.
And a curved block for the inside curves.
I step through each of the grits – 60, 80, 100, 120, 15, 180, 220, 320.
Finally, here is an update on the hours.
Current time log:
Cutting rough stock: 2 hr
> Cutting to width and thickness: 4 hr 20 min
> Cut to final length: 3 hr 30 min
> Shaping: 5 hr 50 min
> Mortises: 10 hr 35 min
> Sand & radius edges: 19 hr 35 min
Seat Back and Back Rest
> Cutting thin stock for laminations: 3 hr 35 min
> Prepping laminations: 8 hr 40 min
> Glue up Laminations: 3 hr 50 min
> Trim Laminated Parts: 2 hr 25 min
> Tenon: 5 hr 40 min
> Mortises: 5 hr 30 min
> Sand & radius edges: 6 hr 10 min
> Cutting thin stock for laminations: 1 hr 55 min
> Prepping laminations: 3 hr
> Glue up Laminations: 6 hr 5 min
> Trim Laminated Parts: 30 min
> Tenon: 2 hr 50 min
> Sand: 7 hr 35 min
Lower rail parts
> Cut to width and thickness: 10 hr
> Cut to length: 1 hr 30 min
> Mortise: 4 hr 35 min
> Tenon: 28 hr 30 min
> Sand & radius edges: 15 hr 35 min
> Cut to size: 1 hr 50 min
> Shape: 1 hr 50 min
> Tenons: 35 min
> Holes: 1 hr
Total so far: 168 hr 50 min (28+ hrs per stool)
-- Steve - Impatience is Expensive