Confession – I finished the upholstery several weeks ago but have not gotten the blog updated until now. Oh well, everything else about this project has been on its own pace so there is no sense in changing now;)
Here we go. The next step is to cut seat blanks. I used a sheet of good quality 3/8 plywood.
I printed out a full size pattern.
Cut it out on the bandsaw.
Sanded it smooth.
I then used the first cutout as a pattern for the other 5 seat blanks.
I used a brad point bit to mark the hole locations.
I used a T-nut to bolt the seat blank to the stool.
As always with this project. I keep moving on and eventually I get to the end of each step.
After the seat blanks are done, its time to cut the foam. I used 1 1/2 inch thick blocks of upholstery foam. I used the bandsaw to cut to shape and then tapered the foam.
I took out the bandsaw table insert so I could tilt the table as far as possible (I would guess 50+ degrees). The seats were cut about 3/8 inch oversize and the taper ended up just over an inch inside the seat outline.
The foam is glued to the seat base with spray adhesive. After the foam is bonded, the edges are bent over and stuck to the seat. This gives a pretty good shape to the seat even before fabric is added.
After the foam, next is a layer of muslin.
This is followed by the final fabric. The pattern is located and stapled front & back.
Then the sides & corners.
Trim the excess.
Add heavy paper.
And – finally – bolt the finished seat to the frame!
Here is a view of the final seat.
I’ll save the final pics for the project posting – given past behavior that could take a while ;)
Here is the final 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
> Seat Blanks: 3 hr 55 min
> Foam: 1 hr 20 min
> Muslin: 4 hr 15 min
> Final Fabric: 7 hr
Total: 245 hr 15 min (~41 hrs per stool)
-- Steve - Impatience is Expensive