Wegner-Inspired Deck Chair #15: Back rails weaving slots

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Blog entry by Ross Leidy posted 05-24-2020 04:34 PM 283 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 14: Final mortises? Part 15 of Wegner-Inspired Deck Chair series Part 16: Final shaping and start of glue-up »

The back of the chair will be woven at the same time as the front, and there’s a clever technique that was used to hide the knots when sections of cording are tied together. Caleb James details this in a two-part article in Popular Woodworking, which I bought just for the weaving part of this project. The back top and bottom rails each have a slot that allows the weaving pattern to be altered on the back side while the front continues normally. The back side pattern creates a vertical band of cords that allows knots to be concealed behind it.

With the layout lines drawn, I eyeballed the placement of a router template and then cut the slot as deep as I could.

For cutting the remainder of the slot, I indented to use the 1/4” flush cut bit I used earlier for the leg slots. Unfortunately, when I started the router with the bit inserted into a pre-drilled hole, I didn’t have a grip on the rail and it spun and broke the bit.

So I switched to the drill press to drill out the bottom of the slots, and then cleaned up with a chisel and round file.

Time to start rounding-over the pieces. I decided not to mess with the width of the stretchers/rails. Due to the mortises in the ends of the curved pieces, if I trimmed the ends a bit, the tenoned joint would shift and make a larger reveal than I wanted. So I decided to continue on with the existing width.

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