Jensen-style Z-Chair #21: Side structure - Edge round-overs

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Blog entry by Ross Leidy posted 06-23-2019 09:54 PM 246 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 20: Back stile tapers Part 21 of Jensen-style Z-Chair series Part 22: Side structure - Glue-up »

If you happen to look obsessively at photos of the Z-chair, you’ll notice that outward-facing edges of the side structures are rounded more heavily than the inward-facing edges. This reduced round-over makes practical sense at the top of the back stiles, where too much rounding would eliminate the flat surface where the rail attaches. To a lesser extent, the same applies to the front seat rail.

To replicate this (or approximate it), I’ll use a 1/2” radius bit at full depth for the outside round-over and the same bit retracted into the router table a bit for the inside round-over so that it would only cut about 1/4” in from the edge. (The upper rail sits about 5/16” in from the edge.)

Test block:

Now on to the chair parts:

Where there was risk of tear-out, I rounded over later with a rasp.

Then after some sanding down to 220, I did another dry fit to check out how things look.

Getting there!

2 comments so far

View sras's profile


5110 posts in 3547 days

#1 posted 06-24-2019 05:22 PM

It’s coming along nicely! I’ve been enjoying the process.

-- Steve - Impatience is Expensive

View kaerlighedsbamsen's profile


1298 posts in 2132 days

#2 posted 06-24-2019 07:18 PM

Good to see that you are carefull doing the roundovers. We see a bit too much thoughtless rounding over all parts in here

-- "Do or Do not. There is no try." - Yoda

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