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Woodworking blog entries tagged with 'shou sugi ban'

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Wegner-Inspired Deck Chair #21: Weaving the seat

06-15-2020 03:10 PM by Ross Leidy | 11 comments »

Finally, the weaving! It goes slowly, but it’s kind of relaxing. I’ve accumulated a number of progress photos over the last few day, so here’s how it’s going. I’ll post some final seat photos once it’s completely done. We’ve been having such nice weather most of this last week, I worked out on the deck for this step. I’m sure this helped make this a relaxing process. One bonus I found with working with paracord is that I don’t hav...

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Wegner-Inspired Deck Chair #20: Final prep before weaving begins

06-07-2020 06:14 PM by Ross Leidy | 1 comment »

I left the chair to cure a few days after 3 coats of poly, and then finished the last few steps to prep for weaving – attaching the add-on weaving slots and installing a bunch of screws that will take the place of the Danish “L” nails. In this soft wood, the nails would likely work loose after a while, so I instead I used some stainless screws that have about 3/8” of smooth shank at the top. These were installed according to the template from Caleb James’ weavi...

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Wegner-Inspired Deck Chair #19: The burning!

06-01-2020 04:28 PM by Ross Leidy | 4 comments »

I waffled many times since the start of this project on whether to follow-thru with using the shou sugi ban technique to get a black finish. But, armed with a number of trials on scraps of the same lumber, I gathered my courage and plunged ahead. I’m very happy with the result. Here are a few photos of before, during, and after. I finished-off by brushing an initial coat of General Finishes Exterior 450 flat. I mixed-in some graphite powder to help tint some areas that were less ch...

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Wegner-Inspired Deck Chair #18: Add-on weaving slots

06-01-2020 02:11 PM by Ross Leidy | 2 comments »

I appreciate the cleverness of hidden little details like these. It took a while to find photos of the bare structure of either a CH-25 or CH-27 (without cord or caning). I wondered how they were able to weave around obstacles like where the arm joins to the back stile. The answer was simple and clever – a tribute to the craftsman who built these chairs. They installed additional weaving slots to provide an alternative return path for the cord to avoid the obstacles. To weave my ...

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Wegner-Inspired Deck Chair #17: Final glue-up

05-28-2020 01:53 AM by Ross Leidy | 3 comments »

After a final dry fit, I did a little bit of final shaping, drilled the holes for the seat weaving bars, and glued-up the rails to the side structures. The front legs, the stretcher between them, and the arms will be a separate glue-up. Holes in the rear seat rail for the weaving bars. There are matching holes drilled in the front seat rail. Little bit of shaping. Weaving bars installed. Clamped and checked for square. I let the glue dry on those pieces be...

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Wegner-Inspired Deck Chair #16: Final shaping and start of glue-up

05-24-2020 07:41 PM by Ross Leidy | 2 comments »

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...

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

05-24-2020 04:34 PM by Ross Leidy | 0 comments »

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 vertica...

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Wegner-Inspired Deck Chair #14: Final mortises?

05-22-2020 02:11 AM by Ross Leidy | 2 comments »

Not much to show for today’s work. I made the arm-to-back-stile mortises (the final ones for the chair) and then tapered the top of the arms on the bandsaw and planed them to clean them up. I’ll soon be at the place where I’ll need to complete the edge round-overs on each of the pieces. One last thing I may do is to shorten all the stretchers a bit. I think that the chair is a little wide, a little off in its proportions compared to the original. I expected th...

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Wegner-Inspired Deck Chair #13: Arm-to-front-leg mortises

05-19-2020 02:09 AM by Ross Leidy | 3 comments »

The technique I used to mark the mortise locations on the arms was fiddly to get right, but in the end it worked out. On the top of the front leg, I transferred its mortise layout lines onto the leg’s sides so they could be seen from underneath when the arm was in place. With the front leg clamped into its correct position front-to-back and side-to-side, I set the arm in place and then laid on my back to transfer the marks from the legs to the underside of the arm. I probably took 30...

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Wegner-Inspired Deck Chair #12: A start on the arms

05-17-2020 10:27 PM by Ross Leidy | 0 comments »

There are a few things about arms that make them a bit of a pain to setup, and this was one job I definitely wanted to “mark not measure”. I started by temporarily fixing the front leg in place so that it was perpendicular to the rail. This was necessary to set the angle of the flat top the leg, which defines the angle of the armrest, which then dictates where the base of the arm meets the back stile. A few pictures will help. I started with an arm template. I toyed with th...

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