With all the mortises finished, I can finally take the pieces back to the router table for final shaping, which was a combination of different radius round overs – 9/16”, 1/2”, and 1/8”. In some places I stopped short and then blended those areas in with rasp and sandpaper.
The underside of the long side piece where the front leg attaches:
The hook at top. 
After a few sanding sessions, I had all pieces ready for assembly.
The first things to glue were the main side piece to the back. The Microjig clamps were ideal for this. I’ll blend the rear-facing side of the joint later.
Once the glue is dry for both of these main side structures, I’ll do one more dry-fit to both check the arm fit again and to drill holes in the front and rear seat rails (forgive my haphazard mix of terminology throughout the project). The holes will hold captive a pair of stainless weaving bars that will be used during the side-to-side weaving process.
2 comments so far
kaerlighedsbamsen
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1343 posts in 2493 days
#1 posted 05-25-2020 11:41 AM
That is a lot of complex shaped piezes to make a chair. Wonder if you want to make a version in nice hardwood as you now have all the templates etc?
-- "Do or Do not. There is no try." - Yoda
Ross Leidy
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173 posts in 2721 days
#2 posted 05-25-2020 01:55 PM
You are right about that. I’ve already decided that I won’t make the 2nd one out of construction lumber. But I’ve definitely learned some things with this chair that I can apply to another made from hardwood.
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