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Well the chairs are completely finished!!!    The upholstery guy gave me a call this morning that he had the seats done. Super happy how they turned out. Put them all on and moved the chairs to

Spent the last week or so gluing up the back leg assembly. Could only do a couple at a time as that is all my clamps would allow me to do without using some 6’ clamps. Need to get some pipe cut to bet

Got to work tonight cutting the mortises.  Started with the mortise on the back leg that attaches the side seat rail. Had to make a template to support the back leg. Template has a couple marks o

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Didn’t get a whole lot done on the chairs since Friday, did manage to get the front leg assembly’s glued up and started to pin them. Am using 1/4” dowels to do the pinning. Have made a few templates to help mark them out. Drilled about a 1/8 hole in the template to mark with an awl then use a Brad point to drill the hole. 4904D1A0-727C-4004-9DDF-0AC98C5EBA22.thumb.jpeg.b58f0be6d1404d49247ec929d55795a1.jpegD041DD34-E504-4207-B222-EACB8ABF8892.thumb.jpeg.6f8c1d3baf0288f0c5b26843a733edc7.jpegA7B2FC3C-26A7-4B03-8475-A5D7C6E2596A.thumb.jpeg.c85e084e287997e7048a50e0554c905a.jpeg
Had a little squeeze out that I cleaned off with a wet rag. 3F8109C8-932A-42B8-8CA4-E3EED91FED74.thumb.jpeg.122c99b00be2af06ab6586cfd1bed349.jpeg

Have to say the flush cut saw I got off Amazon works dang well! Didn’t expect much for what I paid for it but have to say I am impressed. Have had it for a little time so don’t remember what I paid for it exactly but it sure makes the grade. 
 

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Nicely done!

 I make jigs like this all the time but, usually mark directly with the drill bit in the drill.  If you wallow the hole a little, are you ever going to notice from one location to another?  Most likely not but, it does cut out a step and if you're doing a bunch of them, that adds up.

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10 minutes ago, Kev said:

Nicely done!

 I make jigs like this all the time but, usually mark directly with the drill bit in the drill.  If you wallow the hole a little, are you ever going to notice from one location to another?  Most likely not but, it does cut out a step and if you're doing a bunch of them, that adds up.

You know I think you are right. Could mark it with the Brad point,  guess I just didn’t see skipping that step as I was more concentrated on having the bit spinning pretty quickly while starting the hole to try avoiding some tear out. Great advice. I’m gonna use it!

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We are getting closer with this project!

 

The side stretchers with their angled tenons all got remade turned out well but I didn’t want to chisel off the remaining portion of the tenon. With it being angled it made it a little challenging to get the angle set just right but was worth it in the end. Made 2 setups for the left and right sides. 9F874254-1FD1-4CA0-A534-921E0A93CBAB.thumb.jpeg.5a477be883de2ec8e5a96ba8a90c52b1.jpeg

E7806128-48EF-49A6-A3A4-9359B698411D.thumb.jpeg.d03e5ad5d5b3f61aa3bcc8226e620c41.jpeg

Used a sliding bevel gauge quite a bit in this project. Using it here to set the angle of the sliding miter gauge. BB5234BD-F483-49C2-AFD4-97FA32AC065B.thumb.jpeg.c37c037cd986104c0ca1bb0c5f13c92a.jpeg

After getting all the upper stretchers cut, I dry fit a chair to get a measurement for the lower stretchers. With the lower part of the chair angled back it adds a degree of difficulty to these parts. Not only do the have a splay angle but also an angle to match the leg. 41014027-7CAD-460F-AB0F-BC91C0852697.thumb.jpeg.f48aedbf81645f902421fdbee437501e.jpeg1F3F7CBE-4B20-40F5-B7AF-EA768FAD4BC8.thumb.jpeg.424008af06b1b45964b6bf1f3e621c6b.jpeg

Made all my cuts referencing the face. Looks a little sketchy holding the pieces this way but actually wasn’t as bad as I thought it would be. With the tenon jig I made my hands stay quite a bit away from the blade in this operation. 0A7B1B26-C133-4D0E-8CE3-D78CC021A2C5.thumb.jpeg.e4209b8f4ff70f0c0d54027a99433f59.jpeg

Hard to get a picture of the double angle in these parts as it’s a 7 degree splay and 14 on the shoulder. B97CA554-7DC9-46FF-8A00-8B43D5E05041.thumb.jpeg.552a5eae2d083e9787ec03cbd47ab442.jpeg

Was very shocked and excited how well they fit together. This was a dry fit that I was able to squeeze together by hand but fits tight enough that some slight convincing with a hammer to get them apart. 

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5 minutes ago, Kev said:

Always a good feeling when those head scratchers come together!  Nice work!

Yea I will say I was very proud of it! It’s was very demanding of attention cutting these stretchers. It was over 5 hours of concentration and test cuts. Couldn’t really test fit till they were completed, which added to the stress. Still have to cut a little off the height to make them fit the mortises which is also at an angle. Did the one set just to check the fit. 

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Wow good job I don’t have that mind power when it comes to angles. My wife makes fun of me anytime I have to do an angle other than 45 an 90. I just sit there all dazed an confused. Way to much thinking going on. You can pull it off tho those sure are some nice chairs

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  • 2 weeks later...

Life has been a little busy since my last update on the chairs. Have been getting in a little shop time the last couple weeks and have chairs all over the place! 
 

Have been getting fronts attached to the backs of them. Takes a little time to get the parts sanded and cleaned up before mating them. Figured this would be quite a bit easier to have 95% of the finish sanding completed before the chair was final assembled. 952D15B0-A4E0-45F6-8A6E-A0B7746BA789.thumb.jpeg.8dec910c1dca49af0b307fccc8e74721.jpeg

With all the parts not being that easy to get good clamping pressure I made a few little blocks to help. They work well but trying to get the glue spread and blocks in place can be a little stressful. Have had some assistance in just holding an end of a clamp from my neighbor, wife and daughter. Did a couple on my own and invented a new language while doing so. 1A5D8780-1CA9-4B48-9CCB-895F2B35AE52.thumb.jpeg.f3c237749f21797cfd02b31f08a35cbf.jpeg

Made some cushion hold downs out of the messed up side stretchers, didn’t use them all up but shrunk the fire wood pile some. Marked a couple lines which are hard to see on the fence to center them up. 2D71F0F2-F482-4FF5-9410-B5614B685E64.thumb.jpeg.c4bf1de3b832e398be242556996bcfdb.jpeg

with the chair out of the clamps I installed the hold downs along with a glue block in the front corner for a little added support. Also after they are out of the clamps the side stretchers also get a dowel pin installed in them. Didn’t get any pictures of that as it’s the same process that was used on the leg sections. A400185C-E6ED-414C-AE0E-CC33948A32AF.thumb.jpeg.5b05e5ae7cdcf41bd1735bc6856b1e21.jpeg

Got a seat back from the upholstery guy! He wanted to take a stab at one to see how we liked it. Must say he has gone way over my expectations, the day after I picked this seat up he called me up asking how I liked it and if any changes need to be made. You can’t see it in these pictures but a slight adjustment is going to be needed on the fit of the back of the seat, nothing major just the corner where the fabric is a couple layers thick it bumps the back of the seat out a touch from the back of the chair. He wants me to bring him a chair down when I bring the remaining plywood bases for the seats. 70AF41FC-FF48-4D6F-82EE-AB0347A3F586.thumb.jpeg.94fe8b09af88e6baddb3d798470230b1.jpeg

Currently I have 7 chairs matted 2 ready for stain.  I will admit it was nice to sit on the chair with the seat cushion on. 

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1 minute ago, Kev said:

Those are looking awesome!  I'll take 4!

using the blue tape and CA trick would have saved you a little with your glue blocks..

Thanks! If I would’ve only known about you wanting 4 a couple months ago! 
 

Ya know I did try to tape them in place, only to have them fall off.  Think that’s where the new language came into play. I very seldom think about using ca glue. Not sure why I didn’t think of that. Good advice. With only one chair to go I’m going to use that method to do it. Maybe that way I will realize how valuable that trick is. Thanks! 

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1 minute ago, Jamie said:

Thanks! If I would’ve only known about you wanting 4 a couple months ago! 
 

Ya know I did try to tape them in place, only to have them fall off.  Think that’s where the new language came into play. I very seldom think about using ca glue. Not sure why I didn’t think of that. Good advice. With only one chair to go I’m going to use that method to do it. Maybe that way I will realize how valuable that trick is. Thanks! 

Let us know how it works out!

I could do a "quick shop win" video on this but, it's certainly not my idea or invention!

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Just now, Kev said:

Let us know how it works out!

I could do a "quick shop win" video on this but, it's certainly not my idea or invention!

Will do! Hopefully tomorrow by midday I have it glued up.  Have to get out on the ice to see if I can catch a few early on ?
 

I don’t know who thought of it but it seems like a pretty good idea and should be a perfect approach for this. 
 

On the second or third one I did by myself I ended up using a Irwin hand clamp to hold the back block on, learned to position that clamp at the height where I wanted the pipe clamp to be. Didn’t work to bad but having the extra set of hands sure made it a lot easier. 

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Jamie, that cushion and the color you selected is really going to match the design style of your chairs.  Everything is really coming together.  Great work.

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“If you don’t have time to do it right, when will you have time to do it over?”  John Wooden

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Did get a chance the other day to try the ca glue and tape trick.  What a easy process! @Kev I must say it worked amazing! Didn’t take long and made clamping a breeze. 37E7D71E-D753-4667-A222-54FF9715103D.thumb.jpeg.04e348b9af049a4b3be4735dfd768385.jpegC0A383EA-D4FF-4D73-8FA8-048C70BF326A.thumb.jpeg.5578b3eff7b54d9751ccd0ffe49ace01.jpeg3ABF28B5-D155-467C-93CC-B1682D2144A6.thumb.jpeg.6eb674c654d0725dad854ae582dcf8c8.jpeg

Did run into a little trouble when I removed the clamps.....a little ca glue seeped through the tape and is now firmly attached to the chair. Should be able to sand it off. 

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On 12/27/2020 at 12:00 PM, Chet said:

Jamie, that cushion and the color you selected is really going to match the design style of your chairs.  Everything is really coming together.  Great work.

 

9 minutes ago, Bushwacked said:

these are coming together great!! Those seats look very nice as well! 

Thanks! The color wasn’t my choice I must admit, wife won that one! The upholstery guy has been awesome to work with on these. He took a picture in my head and molded it out perfectly. I actually took him a chair once I could get the front connected to the back so he could guide me in sizing the seat. I can’t complain about the price he told me as well. $30-40 a seat. I am suppling a 3/4 base and he does the rest. 

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You know Jamie a Morris Chair would fit in real nice with the design of these dining chairs ... If you know what I mean. ?

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“If you don’t have time to do it right, when will you have time to do it over?”  John Wooden

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