One Man's Junk - Chair

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Blog series by Zuki updated 07-27-2008 10:47 PM 11 parts 15639 reads 65 comments total

Part 1: The inspiration and the junk

07-01-2008 11:58 PM by Zuki | 8 comments »

As most people have stated this project is going to be a very interesting one. Unlike the Winter Awards and my very secretive Project X . . . with this project I will be an open book. What I plan to make is a chair (as DW claimed my other one) to use at my computer. Here is my inspiration. We have had this office chair kicking around for years. It is still very comfortable and the proportions are great even though it is in very rough shape. And here is the junk . . . the ...

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Part 2: Starting the work

07-06-2008 02:27 AM by Zuki | 5 comments »

Since my last posting I went to the local lumber yard to get some 8/4 poplar. I found a nice board that was 12” wide and had them cut off 36” . . . that made 6bf @ $3.25 bf = $19.50. I then spent some time examining my inspiration. The seat is actually 1” thick made from several t&g boards. I opted to go with pocket screwing the boards together. Here is the blank. I also dressed by 8/4 blank that I will use for the arms and back of the chair. I then dug out some cardb...

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Part 3: Using the Bandsaw

07-07-2008 01:24 AM by Zuki | 6 comments »

I was a little later getting out in the shop today as an unexpected errand popped up. The first thing I did was trace out the patterns on the wood. You can see the seat and the arm pieces sketched out on poplar. I then checked the thickness of the arm pieces . . . I needed 1 5/8” and they were a tad over 1 ¾”. The back pieces of the chair were also 1 ¾ and had to be taken down to 1 1/8”. I dragged out the planer and a few passes later they were in spec. Next it was off...

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Part 4: I hate sanding

07-09-2008 02:20 AM by Zuki | 5 comments »

I hate sanding. Have I mentioned that I hate sanding. If I have not . . . I hate sanding. I left off the previous section with the pieces all cut with the bandsaw in need of sanding. Have I mentioned I hate sanding. Here are what the pieces look like up close. I recently purchased a drum sander kit for my drill press for $28 . . . I think it is a good deal. I was hoping to use it exclusively for sanding these items, however when I carpet taped the matching pieces together the...

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Part 5: Scoopin

07-11-2008 02:17 AM by Zuki | 7 comments »

Tonight I decided to attack the scooping of the seat. I had some concerns when Betsy reminded me about the pocket screws. The first thing I did was to determine how much, if any, room I had to scoop. Using a scrap piece of board and a freshly drilled pocket hole I estimated I had around 1/8 “ to play with. Great . . . now how do I scoop. Hmmmm. After I sketched the scooping on the seat I took out my Mastercraft (Canadian Tire store brand) plunge router and ½ straight bit. I set the p...

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Part 6: Looking like a chair?

07-14-2008 01:27 AM by Zuki | 4 comments »

I find it quite neat with woodworking that after hours toiling with chunks of wood, crafting them into miscellaneous shaped pieces that they all fir together (relatively well we hope) to resemble a final product. Today I worked on the Front Rail, Back Rail, Back Posts, Back Stretchers and seat. I first went upstairs to take some measurements off the model. I then made the Front Rail and Back Rail (which I attached to the Back Posts). I then proceeded to notch the back to the seat ...

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Part 7: Lean on me

07-15-2008 01:10 AM by Zuki | 7 comments »

Not much happened in the shop this evening. I decided to attach the Back Stretchers. Firstly I had to do some marking on the inside of the Back Posts so I would get a good idea on where to drill the recessed holes for the screws. I drilled pilot holes from the inside out and used those holes to guide the bit for the recessed screws. Here I am at the DP. I actually managed to take this picture myself using the timer function. Yea . . . I know . . . all cameras have timers, however ...

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Part 8: Moving right along

07-17-2008 01:04 AM by Zuki | 8 comments »

This is where I started tonight – I attached the back to the seat of the chair. This is what it looks like when everything underneath is attached – front, back and side stretchers. Next on the list is the arms. I placed them up against the chair to see what it will look like. I then cut the end of both arms to match with the uprights. The next step is to remove the area that I have marked in red. The area to be removed would taper into the front curve. I’m debat...

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Part 9: The end is in sight

07-20-2008 08:34 PM by Zuki | 6 comments »

I have not been out of the shop for a couple of days and I had a little mishap on Friday while staining the deck. 99.9% of the time when I am outdoors I am wearing coveralls . . . what I wear underneath is determined by other factors. :-) On Friday I said to myself “self, why not get some sun on your white skin and vitamin D into your system” . . . “I said sure, why not.” For the 2 hours outside in the sunshine I wore a pair of trunks. Well . . . my entire back, one thigh and both forearm...

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Part 10: Plugging along

07-23-2008 12:49 AM by Zuki | 4 comments »

I was late getting home this evening so my time was limited in the shop. My main task was to plug all the holes where I used screws . . . not the pocket screws as they are all hidden. I popped the fence on the BS and lined everything up. This is the first time I used the fence . . . its 4” high and came standard with the saw. I like it. After I ran the plugs through I was left with this. Instead of using any type of wood glue to hold the plugs I use a secret formula . . . ...

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Part 11: Final Entry

07-27-2008 10:47 PM by Zuki | 5 comments »

Im getting close to the final product. Here I am flush cutting the plugs. They are still a little proud, but sanding will take care of that. I decided to spare you by not including pictures of me sanding. I just have one word – dusty. Here it the base that will be attached to the chair. I had a piece of spruce that was kicking around the shop for some time. This was the perfect opportunity to put it to use as the “adaptor plate” for the base and chair. It was a little ...

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