A new dining room set for my wife! #26: Corners done and bottoms up next.

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Blog entry by GaryK posted 05-26-2011 04:54 PM 4520 reads 1 time favorited 6 comments Add to Favorites Watch
« Part 25: Finishing finally done! Now assembly Begins Part 26 of A new dining room set for my wife! series Part 27: The seat backs. Finally all the woodworking is done! »

Getting close to the end!

Here you can see that I added all the corner supports. They were basically straightforward. I cut one at 45 degrees, flipped the board over and cut another and so on. Then I set the miter gauge to 8 degrees and trimmed one side to match the angle of the sides. Then did the same at 8 degrees on the other side of zero for the other end.

Then to the drill press with a couple of brad point bits. First a 5/16” to create a counter bore and then a 3/16” for the through hole. I wanted a flat bottom for the pan head screws I attached them with. I didn’t want a flat head screw since that would probably split the corner blocks.

I used hard maple. I like the way the end grain cuts to so smooth a finish, and their strength.

I probably could have gotten away with just one support in each corner, but I want these to last for years to come. I glued and screwed each one with 2 screws.

Now on to the seat bottoms. To make the first one I just set it in place and the marked it to notch the 2 back corners. Then after I cut them, I put them back in place and traced the final shape using the sides of the chair as a guide.

Note that they were all cut to length and width first on the table saw.

Once I got the first one the way I wanted it, I held it against each of the others in turn and traced lines to cut to. I just cut them on the bandsaw since they aren’t critical.

Then I placed my first one in place again and traced the inside.

Then I drew a line diagonally. This showed me where I needed to drill the hole in each corner. These are the holes I will use to attach the seats to the chair. I use a small little drill bit to drill all the holes. I will use this hole as a pilot hole for the bigger holes I will drill later.

Then I use that first part as a template for all the holes in the other seats as well as the corner blocks in the chairs. This will assure that all the seats will be able to fit any chair. All interchangeable.

Here you can see I am drilling all the holes in the chair corner blocks. These holes will eventually be opened up to 5/16”.

Then I also open up all the holes in the seats to 5/16” also to accept the T-nuts. They are for 1/4-20 screws.
Don’t even think about going to a big box store to buy them. I bought 100 from McMaster-Carr for about $7.50. Even with shipping they would cost about the same, but you end with a lot extra.

Here you can see them all complete! One step closer to being done!

Next I will show you how I did the back.

Can anyone guess how I will do it?

Remember it will have to conform to the back, be strong enough and be able to be upholstered.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

6 comments so far

View JonJ's profile


163 posts in 5125 days

#1 posted 05-26-2011 05:03 PM

lookin’ sweet! As far as the curved back pieces…are you maybe going to laminate layers in a vacuum bag or clamp in a mold?

-- Jon

View longgone's profile


5688 posts in 4593 days

#2 posted 05-26-2011 05:49 PM

I am enjoying seeing this chair project come together, Fantastic job and alot of work.

View Lee A. Jesberger's profile

Lee A. Jesberger

6875 posts in 5264 days

#3 posted 05-26-2011 07:26 PM

Great job, Gary.

Super job on the blog.


-- by Lee A. Jesberger

View littlecope's profile


3133 posts in 4787 days

#4 posted 05-26-2011 10:14 PM

It looks like it’s almost time to start chilling the Champagne for the end of this…
This has been nearly as much fun for me to read, as it has for you to do Gary!!
Excellent Work!!

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Karson's profile


35279 posts in 5685 days

#5 posted 05-27-2011 12:41 AM

Very good gary. Nice set of blogs.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View HallTree's profile


5666 posts in 5052 days

#6 posted 05-27-2011 05:48 AM

The backs: two sheets of thin plywood bent and glued together in a form of some sort?

-- "Hold on to instruction, do not let it go; guard it well, for it is your life" Solomon

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