Four production side chairs were completed this week.  The design is original.  Primary material is cherry.  The seat is made from hard maple with two cherry accent pieces and was scooped using the TS.  The back support has both cherry and maple splats and the rails are curved along a 33” inner radius.  The chair is finished with BLO and precat lacquer.  The design has a lot of angles, particularly the lower stretchers.  The stretcher assembly uses loose dowel-tenon joinery, so there are 24 mortises and 16 angled surfaces that must play nice with each other.  The rear legs are taper on three sides to 1-1/4" x 1-1/4" and have a subtle castle detail added.

You can follow the prototype design/build here.

 

Danl

 

Fantastic!

 

Love to read more on how you sculpted the seats.

Edited June 26, 20206 yr by lew

Awesome!!!

Nice, yes sir, very nice.

Beautiful! Sturdy, too. Well done!

3 hours ago, lew said:

Love to read more on how you sculpted the seats.

Me too.  Did you use a technique similar to cutting cove molding on a table saw? 

+1 on the positive comments.  That whole set is simply awesome.  Love the legs on the table.

Edited June 27, 20206 yr by FlGatorwood

Fantastic job. That cut at the top of the chair back rails is very cool

Very nice.  I know there are very few square corners on a chair.  The big debate is "angled mortises or angled tenons."   Sort of like "pins first or tails first."

That is a gorgeous set Danl, thanks for sharing with us.

On 6/26/2020 at 8:10 PM, PostalTom said:

Me too.  Did you use a technique similar to cutting cove molding on a table saw? 

Mario Rodriguez has an interesting technique for this.  Not tried it, but a friend has.
 

 

It looks like the most involved part of the process is making the jig. @kmealy, did your friend say how he or she liked the outcome of their seat?

23 hours ago, kmealy said:

Very nice.  I know there are very few square corners on a chair.  The big debate is "angled mortises or angled tenons."   Sort of like "pins first or tails first."

The key is to know how your plan to assemble the chair for glueing.  The joinery for the seat rails and stretchers are loose mortise and tenon.  The rear and front legs mortises have to be co-planer.  So, the mortises in the rear and front legs are 90-deg, but the mortises into the rails and stretchers are angled.  End result is having an angled tenon.

The joinery for the back support rails are M/T.  and the tenons are at 90-deg.

Danl

 

Back support rails with integral tenons

 

Rear leg receiving mortise for side seat rail tenon

 

Side seat rail receiving angled mortise for loose tenon

 

Side stretcher receiving angled mortise for loose tenon

 

48 minutes ago, PostalTom said:

It looks like the most involved part of the process is making the jig. @kmealy, did your friend say how he or she liked the outcome of their seat?

I did mimic the Mario Rodgrigiez technic with a few changes depicted in the pics.  After initial TS set-up, I can make 93 TS set-ups and have the seat blank ready for sanding in 1:35 min.  Maximum material removed is 1/16" per set-up.   Danl

 

 

 

 

 

 

 

 

Thanks for the explanation

1 hour ago, PostalTom said:

It looks like the most involved part of the process is making the jig. @kmealy, did your friend say how he or she liked the outcome of their seat?

not that I heard

Wood "weight" trivia.

I wanted to make two seats from hard maple and have the long grain be on the top side.  I purchased 8/4 lumber.

8/4 x 8-1/2" x 10' weighed 53-1/2 lbs.

 

I only needed ~ 6'

8/4 x 8-1/2" x 6' weighed 32 lbs

 

I made two blanks 18" x ~18-1/4" x 1" 

weighed 17-1/2 lbs

 

After scooping and profiling the seat blanks, the two seats weighed 9-1/2 lbs

Danl

 

Amazing process and results.  I am impressed.  

Some high level stuff !!!,...the pic without the seat that shows all of the framing is my fav. Sturdy,...beefy,...well executed. 

Thank you all for the kind words.

Danl