After I got the parts all finished, I was really excited to do a dry fit and see how everything looked. I didn’t even bother to change into any shop clothes!
As you can see, tongue position is important when dry fitting pre-finished parts.
Before I actually glued up an assembly, I dry fit the stool. The corner blocks are then set in place. The tenons on the corner blocks needed a little fitting to get them into position. Pilot holes for the screws were drilled and then the stool is disassembled. Then I set the parts out to make sure I have everything ready to go.
I also make sure the clamps and clamping jigs are in order.
Gluing up an entire stool at once requires a glue that has a loooonnnng open time. I am using epoxy. I learned about epoxy assembly from building kayaks a few years ago.
This epoxy needs to mixed in a 2:1 ratio (resin:hardener) by volume. You can use pumps to meter out the portions. Others use scales that account for the ratio and density differences. I find it much easier to measure out volumes. I use old pill bottles to do this.
I mark the left one to measure out a single part of the mixture. I then pour water to that level and transfer two parts into the right container and mark that level. I then add one more part and mark that level. I then empty the water out and dry it well. I then add resin to the first mark and hardener to the second mark.
The epoxy needs a structural filler to create strong joints. I also added a little mahogany sanding sawdust to tint the mixture. The entire tub of sawdust was collecting from sanding all the parts . I reserve some of the epoxy to pre-wet the joint and the rest is transferred to a cup and the fillers are added.
I use an acid brush to pre-wet the tenon and the mortise. This is a very thin layer as I do not want to deal with a lot of squeeze out. As I understand it, the pre-wetting allows the wood to absorb some epoxy and helps prevent epoxy being wicked away from the joint.
I then spread the thickened mixture on the walls of the mortise.
The assembly sequence is the same as described in the gluing jig post just before this one. After the parts are clamped, the corner blocks were glued and screwed into position.
The masonite surfaces on the clamping pads worked very well. I had no marks from clamping. There was very little epoxy squeeze out. When this did happen, ithe wax on the parts made clean up quite successful. The final results looks very nice.
I paid close attention to making sure all four legs were in contact with the floor after clamping. I unclamped it and it was rock solid on the shop floor. When I brought the first stool into the house and tried to rock it, there was a slight “tick-tick-tick” as I wiggled it. Rats – not perfect, but close. Shop floor must not be flat. With the next stool, I made sure I found a perfectly flat spot on the shop floor.
The second stool was dead square – even when turning 90 degrees. Brought it into the house and it was rock solid. Then I put it in place the first stool sat – “tick-tick-tick”.
Ah- HA! My kitchen floor is not flat!! The rocking is really slight and goes away when I put my weight on the stool.
They look really nice and are now ready for seats.
They all look good sitting in their final home.
The finishing process took about 11 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
> Oxidize and Final sanding: 3 hr 10 min
> Prep for finish: 1 hr 25 min
> Finish: 12 h 15 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
> Oxidize and Final sanding: 1 hr 20 min
> Mask & Prep for finish: 20 min
> Finish: 2 h 45 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
> Oxidize and Final sanding: 1 hr 30 min
> Mask & Prep for finish: 40 min
> Finish: 4 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
> Oxidize and Final sanding: 3 hr 40 min
> Mask & Prep for finish: 2 hr 30 min
> Finish: 12 hr 5 min
> Cut to size: 1 hr 50 min
> Shape: 1 hr 50 min
> Tenons: 1 hr 15 min
> Holes: 1 hr 30 min
> Remove Masking Tape: 1 hr 30 min
> Dry Fitting: 4 hr 20 min
> Glue up: 6 hr 50 min
Total so far: 229 hr 5 min (~38 hrs per stool)
-- Steve - Impatience is Expensive