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Designing a Chair

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Blog series by Dave Rutan updated 11-07-2014 03:47 PM 5 parts 10068 reads 19 comments total

Part 1: Church Chair I

10-15-2014 04:27 PM by Dave Rutan | 5 comments »

[Above and below] These first two pictures show my first ‘thrown together’ prototype for a stackable, easy to build chair. The finished product won’t resemble it very much. The picture below shows the Mark II in partial glue up. You might notice the tapered legs and back. This one is made of some high quality particle board that I was given. Using it for this is better than just throwing it away. I’m going to be sitting in Mark II for a while to test it o...

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Part 2: Chair II

10-16-2014 06:07 PM by Dave Rutan | 2 comments »

Two views of the second prototype for my chair. This one is made from particle board and is completely glued together. I’m going to use it at the supper table for a few days and see if it’s uncomfortable. I already incorporated one change into this chair, the front stile will have the seat run out on top of it. The original design had the seat more or less as a shallow tray, a little hard on the legs without a cushion. Also a reminder, I have to build a cajon now, so we&#...

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Part 3: Chair III: 1st Bent Lamination

10-25-2014 09:22 PM by Dave Rutan | 6 comments »

Last night I grabbed some particle board that I have in the shop and made a bending jig for the chair back. The chairs are for the table I made for our church. Although I’m glad I had the particle board to use instead of ‘good’ plywood, I got really frustrated with my band saw while cutting out the bending form. Lately I’ve been getting along with my bandsaw but this was miserable. I cut the curve out of two boards and the switched to my jig saw because it̵...

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Part 4: Chair Saga Part IV

11-04-2014 08:41 PM by Dave Rutan | 2 comments »

Above: Take IV on the chair design. Sharp eyes will note that the seat is shorter and the wood overall is 1/2 inch narrower all around, 3 inches down from 3 1/2 inches. This version is screwed together without glue because I anticipate disassembling it and using the parts as patterns for production models. The clamps are holding the ledge pieces on which the seat will rest. They are glued on because I can work around them. Below: How to turn your table saw into a saw table: This chair...

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Part 5: Chair Saga Part V Final Chapter

11-07-2014 03:47 PM by Dave Rutan | 4 comments »

This is my last proof of concept/prototype. From here on it’ll be a build and the project entry will be a tutorial. As you see I threw some stain on it to get a good idea on how it will look. (Dark colors are slimming, no?) I used the same stain as the table the chairs are destined for. This last chair is held together exclusively by screws, screws and more screws, highly visible screws! The production model will be glued with hidden screws for peace of mind. The plan is to take thi...

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