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Occasionally we are able to get some oak 2x4s for use in the rear legs of our chairs. These are rare, so when we find them, we buy all we can get. If we can't get them, we have to laminate 1x boards together to get the thickness we need. Either way, we'll begin the chairs by cross cutting the boards to 41" lengths and using the table saw to create one smooth edge. Then we lay-out the back legs using a template. |
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Using a band saw, we cut out the dog-leg shape of what will be the back of the chair. We use a surface planer to smooth the flat faces and bring them down to 1½" thick, then use hand planes to remove the band saw marks from the other faces. |
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Then the legs make a trip through the router table to round over the sharp corners. We'll do some sanding on especially rough spots, then stack the parts out of the way until we're ready to start cutting mortises. |
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Next we plane lumber to the proper thickness and cut the blanks that will become all the smaller parts of the chairs; seat rails, spreaders, back rails and slats. |
(BELOW) Now that all the blanks are ready, we begin milling them into parts. Marie lays out the mortises in the front and back legs and the upper and lower back rails. Doug cuts the mortises. And Dolly uses a shop built jig on the table saw to cut the tenons on all the rails and slats. |
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When we cut the tenons on the table saw, we cut them just a hair over-sized. Now we trim them down to an exact fit using chisels and sandpaper. Then we assemble the whole chair -- without glue -- to make certain everything fits properly. |
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When we're confident it's right, we begin gluing up sub-assemblies. We check carefully to see that the frame of the back is square. |
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While one of us fits and assembles the backs, the other turns the front legs. The mortises were cut and fitted before turning, so we know they'll fit when we're done. Finally, the front leg assembly is joined with the back assembly with seat rails and spreaders. We use a flat surface for final assembly and adjust the clamps to correct any minor irregularities so all four legs sit squarely on the floor. No wobbles. |
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With the frames assembled, Marie takes them outside and applies a coat of oil based sealer, and enjoys some of our wonderful Tennessee weather. |
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We seal the frame before we mount the seat so that we can be sure that all of the wood is adequately covered. We'll do the same with the seat, then join the two together. |
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For the seats, we prepare the lumber then pick boards that go together well - matching grain and coloring as closely as possible - and glue them together. After setting up overnight, we cut the seat blanks to finished size and shape, round over all edges and sand them smooth. Now they are ready for the first coat of finish. |
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As a friend of ours once quipped, "Now THAT'S a chair you could take into a bar brawl and expect to win."
We have not tested that assumption.
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