Orchard Street Sofa #5: Yes, I have a pair of arms

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Blog entry by AandCstyle posted 02-18-2016 12:09 AM 1580 reads 0 times favorited 7 comments Add to Favorites Watch
« Part 4: Ecstasy!! Part 5 of Orchard Street Sofa series Part 6: Progressing to the leg tenons »

I removed the second arm from the bending form, cleaned up one edge and cut it to width and jointed the sawn edge. I am ecstatic to report that the arms match! Admittedly, there is a 1/16” variance, but since they will be at opposite ends of the sofa (about 80” apart), I am not concerned. :)

Today was all about mortises and tenons. Since I use a Mortise-Pal, I set it to width and then mark the center lines of the mortises I need to cut. Here are the side rails:

And, here are the side slats:

Below are the results on the rails.

I sand the edges that will receive the slat tenons before cutting the slats to final length because sanding can change the dimensions causing unsightly gaps. DAMHIKT

Once that is out of the way, I assemble the framework and hold one end of the slat against the rail.

Then mark the opposite end. Sorry, my photog wasn’t willing to lend a hand. Hopefully, this is understandable as is.

Once the tenons were prepared (same process as yesterday), I got to dry fit everything.

You might be able to see a 1/64” gap, but I think (hope), the clamps will eliminate it during the gluing phase. Finally, for today, here are the two ends.

Please be patient, the paint is almost dry. haha

-- Art

7 comments so far

View Luddite's profile


231 posts in 1844 days

#1 posted 02-18-2016 12:26 AM

Great stuff. I admire your precision with layouts. Do you square out the mortises or just round over the slats to fit?
This just gets better with each new entry.

-- T Loftus -- Just on the edge of common sense

View pintodeluxe's profile


6034 posts in 3419 days

#2 posted 02-18-2016 12:26 AM

More nice progress. Keep up the excellent work.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

View Alongiron's profile


654 posts in 3298 days

#3 posted 02-18-2016 12:37 AM

Great work Art! everything seems so precise and perfect ! Keep up the good work!

-- Measure twice and cut once.....sneak up on it! Steve Lien

View Mark's profile (online now)


1024 posts in 2580 days

#4 posted 02-18-2016 12:45 AM

Taking shape nicely Art. As long as the pieces aren’t bottoming out on the tenons, the clamps should take up the slack. Yer not wasting any time I’ll give ya that.

-- Mark

View AandCstyle's profile


3263 posts in 2862 days

#5 posted 02-19-2016 01:14 AM

My thanks to everyone.

Do you square out the mortises or just round over the slats to fit?

Terry, I use a round over bit on the router table to round the edges and fine tune with a disk sander.

-- Art

View CampD's profile


1807 posts in 4091 days

#6 posted 02-19-2016 02:14 AM

Ain’t it nice when an first assembly goes and stays together almost perfect without clamps!
Lookin good.

-- Doug...

View AandCstyle's profile


3263 posts in 2862 days

#7 posted 02-21-2016 12:39 AM

Thank you, Doug.

-- Art

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