Greene & Greene Gamble House Side Chair #31: Final Wrap Up

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Blog entry by TungOil posted 04-21-2019 02:44 AM 517 reads 0 times favorited 4 comments Add to Favorites Watch
« Part 30: Stain and Finish Part 31 of Greene & Greene Gamble House Side Chair series no next part

Here are the project totals, for those that are interested.

Board feet of Sapele used: 315
4’ x 8’ sheets of 3/4” baltic birch plywood: 2
Number of chair parts fabricated: 285
Number of mortises: 720
Number of floating tenons: 360
Number of square ebony plugs: 405
Number of ebony splines: 120
Quarts of finish used: 10
Hours to complete: 596

What worked well?

I spent about 40 hours drawing templates in AutoCAD to be cut by CNC at the start of the project. I made some minor adjustments to replace dominos with the the standard mortise sizes available with the Leigh FMT. This was time well spent as it made the fabrication go very smoothly.

The Leigh FMT jig again proved worthwhile. This is a well made tool and makes beautiful, precise mortises. With 720 total mortises on this project, I gave it a good workout.

Carefully planning and thinking through the steps of construction and assembly for these chairs was key to making sure they came together successfully.


I broke a few of the smaller 3/16” loose tenons while dry assembling and disassembling the chairs. Using a 1/8” chisel I was able to extract the broken tenon pieces without damaging the mortises.

The biggest mistake was when a dry assembled chair disassembled itself and the back assembly fell over, breaking the top of the center back splat.

Luckily it was a clean break and no wood was lost. I squeezed some glue into the break, put wax paper on either side and clamped the splat between clamp blocks.

After it dried I cleaned up the repair with a scraper and it was nearly impossible to see.

Overall this was a fun and challenging project and I’m glad I took it on. A special thanks to Bob Lang for teaching the class and providing advice, and to Darrell Peart for the design that these chairs are based on.

-- The optimist says "the glass is half full". The pessimist says "the glass is half empty". The engineer says "the glass is twice as big as it needs to be"

4 comments so far

View horky's profile


272 posts in 3411 days

#1 posted 04-21-2019 10:51 AM

TungOil, what a great project … both the table and the chaiirs. I have really enjoyed all your updates along the way. I am sure it will be cherished for a long long time.

View pottz's profile


5978 posts in 1465 days

#2 posted 04-21-2019 05:54 PM

thats an impressive list tung,im tiered just reading it-lol.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View EarlS's profile


3033 posts in 2829 days

#3 posted 04-22-2019 11:46 AM

What a herculean undertaking. You ate the elephant one bite at a time. Can’t wait to see the pictures of the table and chairs on the project page.

What’s next on your woodworking agenda?

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

View TungOil's profile


1319 posts in 976 days

#4 posted 04-23-2019 01:59 AM

Thanks guys.

Earl- next project is the Thorsen sideboard, although I might need to slip a small project or two in before I start that one.

-- The optimist says "the glass is half full". The pessimist says "the glass is half empty". The engineer says "the glass is twice as big as it needs to be"

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