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Stickley 406 Bow arm Morris chair #2: Foot stool progress...

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Blog entry by ceshelman posted 01-14-2022 05:54 AM 252 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 1: In the beginning there was nothing... Part 2 of Stickley 406 Bow arm Morris chair series no next part

Work continues on the Morris Chair. More specifically the foot stool.

The foot stool contains 32 mortise and tenon joints. The chair itself has 42. I have never done mortise and tennon joints other than for guitar neck to body joints. I have a special jig for the neck joints that makes them a no brainer. No such jig for the chair so this is a learning experience. I decided to start with the foot stool since the pieces are much smaller and any mistakes that require remaking a part will be MUCH less painful that if I started with the bigger chair pieces. This turned out to be a wise decision.

I decided to cut the mortises with a plunge router and the tenons on the table saw and round the tenons rather then square the mortises. Also going to make all the structural joints drawbore mortise and tenon as I want this chair to last for many generations. I used a Bosch router and edge guide. To make the router more stable I put matching rails in vice side by side to give the router more surface to run on but it was still a challenge to keep the router level.

Laid out the mortises on the foot stool rails and legs gang style to make sure they all lined up.

The first mortises were pretty rough, not lined up well, and just generally not pretty. But they wont be visible in the finished product so they are acceptable.


All the rails with slat all mortised up.

By the 20th mortise they were looking pretty good and I got a little over confident. Long strory short, I wound up misreading one of my carry over lines as a layout line and wound up with a three sided through tenon. Not good! Note to self: Erase your cary over lines!!


Uh, nope. Not supposed to have a 90 deg through tenon.


Nope. Not right from that angel either.


Ok, yep. That is what it is supposed to look like.

This was one of many mistakes made while cutting these mortises, but the only one I couldn’t hide.

ok, time to go make a new leg for the foot stool.



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