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81K views 98 replies 37 participants last post by  kaerlighedsbamsen 
Corbels, Pegs, and Washers

With the two side assemblies glued together, I can now check the fit of the ladder back.
Wood Wood stain Flooring Floor Hardwood

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Once you get the armrests fit, everything else seems to come pretty easy on this project.
Wood Wood stain Flooring Floor Hardwood

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Here is a look at the beveled through tenons in the armrest.
Wood Rectangle Flooring Floor Table

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A 1/4" dowel secures the mortise and tenon joint. This is a fairly deep hole, and is best drilled with a brad point bit. Test the fit of your dowel stock in a scrap board, as a snug fit is key here. Hopefully you have glued the armrest and tenon liberally (including end-grain) to prevent armrest spring-back.
Furniture Table Wood Hardwood Rectangle

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Now I set out to make the 4 pegs that secure the backrest.
Wood Wood stain Hardwood Flooring Plywood

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I mill a length of 1"x1" stock, and chamfer the corners at the router table. Then I cut the peg handles to a length of 2", and drill a 5/8" hole.
Wood Toilet paper Tints and shades Paper towel Art

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Then it's just a matter of gluing 5/8" dowel into the hole. Alternately, you could turn the peg and handle from one piece of wood at the lathe. The pivot pegs are longer than the stop pegs. Basically, just size the dowel to fit the depth of your drilled holes.
Wood Flooring Hardwood Wood stain Varnish

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With the chamfering bit still setup in the router table, I knock off the corners of a 2"x2" block. Then the hole can be drilled, and the washers can be cut free. These simple wooden washers prevent the backrest assembly from rubbing against the armrests.
Wood Wood stain Hardwood Varnish Flooring

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In the last episode we cut the corbels to shape. Now the corbels are glued in place.
Wood Wood stain Hardwood Pet supply Lumber

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Wood Gas Hardwood Creative arts Plywood

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The corbels have a 3/4" wide tongue that fits snugly in a groove. Although a long grain glue joint would have been strong enough, the tongue and groove help to securely register the corbel during glueup. Another reason I like the groove method is that it avoids visible screws that would later need to be plugged.
The rear corbels need one additional step. Cut the top of the corbel to a 7 degree angle to match the fall of the armrest.
Wood Wood stain Hardwood Rectangle Plank

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Next I laminate some leg stock for the ottoman.
Wood Floor Flooring Wood stain Hardwood


Next up will be the ottoman build.
Cheers!
I missed the first parts of your blog Pinto. Got to go back and read the rest. Thanks for sharing this.
 

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Leather Upholstery

I took a leather sewing class to learn how to make the Morris chair cushions.
Brown Wood Flooring Bag Comfort

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The seat cushion and the ottoman cushion require web frames. Here I am milling the half-lap components for the web frames.
Wood Wood stain Flooring Plank Hardwood

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Web frame assemblies are glued together. The seat frame should be sized 1/4" smaller in all directions than the opening in your chair, to allow room for the leather and two layers of batting.
Wood Flooring Floor Composite material Wood stain

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Corner blocks are added to the large seat cushion for additional strength.
Wood Hardwood Workbench Gas Machine tool

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I didn't have a webbing stretcher handy, so I made one from a block of wood and some sheathing nails. Lengths of dowel create a handle.
Wood Musical instrument Hardwood Wood stain Flooring

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I stretch nylon webbing over the frame, and secure it with upholstery tacks.
Wood Rectangle Circuit component Red Gas

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I use #10 or #12 tacks to attach the straps. An occasional staple helps the webbing lie flat.
Rectangle Wood Material property Flooring Tints and shades

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Seat cushion webbing complete. Notice how the straps are woven together.
Wood Rectangle Flooring Gas Hardwood

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Next webbing is attached to the ottoman frame. The ottoman frame should be sized 1/8" smaller in all directions than the opening of your ottoman. This allows enough room for the leather and a single layer of batting.
Wood Table Audio equipment Automotive tire Gas

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This is the underside of the ottoman frame. Notice how the corners are knocked off so it will fit inside the ottoman legs.
Wood Toy Flooring Automotive tire Hardwood

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Next a 12" square piece of 1" thick high density foam is spray glued to the webbing. This helps to crown the shape of the seat cushion.
Table Wood Rectangle Floor Flooring

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How does a woodworker cut upholstery foam? With a bandsaw of course. It works quite well, I might add. In projects where the cushion sits on top of the chair (some dining chairs are built this way), I will cut foam slightly oversized. In this case however, the cushion rests down in the framework of the chair, so the foam is cut to the SAME size as the web frame. I selected 5" high density foam for the seat cushion.
Gas Machine Plant Engineering Tire

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Here at the upholstery class, full-sized templates are made from heavy paper. The templates are used to layout the required pieces, and held flat with several weights. The patterns are traced with a ball point pen, and the leather pieces are cut out.
Table Wood Interior design Flooring Floor

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The seat cushion has 7" square notches removed from each corner. The corners are then sewn up with a blind stitch and a 1/2" seam allowance. Set the sewing machine for 5-6 stitches per inch. We sized the cover to reach 1/2" short of the inside edge of the web frame. That way when stretching the cover over the foam, you can pull it even with the inside edge of the web frame for a consistent look. Turn the seam allowance to one side or the other to direct the seam where it is less visible. The cover is then drawn down and stapled in place with a pneumatic stapler (electric staplers usually don't set the staple fully).
Wood Rectangle Bag Auto part Hardwood

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Cambric nonwoven fabric is added to the underside as a dust cover.
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Seat cushion complete.
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The 3" thick 1.8 density ottoman foam is attached to the webbing with spray adhesive. Then high-loft Dacron (polyester batting) is stretched and stapled in place. Aim for a snug fit that slightly compresses and shapes the foam.
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Trim the excess batting, and the ottoman cushion is ready for leather.
Comfort Fawn Linens Companion dog Wood

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The leather is simply stretched over the ottoman cushion - no sewing here. Start by placing one or two tacks in the middle of one edge. Then stretch across the width and repeat on the opposite edge. Next tack on a third side, and stretch across the length. This way you can pull all the slack out of the leather. Then you can work to the corners. We used tacks to temporarily hold the leather, and staples for permanent attachment.
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Excess leather is trimmed away.
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Cambric dust fabric is applied, just as with the seat cushion.
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Ottoman cushion complete.
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Now we can move on to the backrest cushion.
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Here I am sewing the welting (piping) at the class. I used 3/16" welting cord.
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Start by blind sewing a zipper tape to the bottom edge of the backrest plates. We used a #4.5 nylon upholstery zipper. Cut 1-1/4" square notches out of the backrest plates (all 4 corners). Blind sew the notches shut with a 1/2" seam allowance.
Outerwear Shoe Sleeve Wood Collar

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The welting is stapled to one of the plates. The two plates for the back cushion are then stapled together with a Bostitch P-3 hand stapler. That way the leather isn't moving around as you sew. For the main seam around the perimeter I used a 1/4" welting foot. All seams are made with #69 nylon upholstery thread. Polyester upholstery thread would also work, but it isn't bonded and can fray.
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Here the backrest cushion has been sewn.
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Here you can see the effect created by notching the corners. It is called a faux-box cushion, because it fits the cushion well like a boxed cushion, but only has one central seam.
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We made straps and inserted them on either side of the faux-box corners. When the cushion is inside out, the orientation of the straps is pointing inward and downward. It's best to just staple them in place, and turn the cushions right side out to convince yourself they are positioned correctly.
Eye glass accessory Eyewear Comfort Tints and shades Hobo bag

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We used a #4.5 nylon upholstery zipper. Make sure the zipper slide faces the correct direction (with the cushion inside out, the slide pull will be hidden).
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The backrest cushion is 3" thick 1.8 density foam, wrapped in two layers of Dacron. The first layer is wrapped side-to-side, and the second layer is wrapped front-to-back. The Dacron batting is attached with spray adhesive. Spray the edges as well, and pinch them together to close the joints.
Wood Sleeve Rectangle Linens Comfort

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Next I blind stitched a slip cover, and placed it over the backrest cushion.
Comfort Textile Wood Floor Flooring

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This will help the leather slide over the cushion more easily.
Furniture Rectangle Comfort Wood Table

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The backrest cushion slides easily into the leather cover.
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Backrest cushion complete.
Brown Wood Flooring Bag Comfort

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Finally I can install the ledger strips that support the seat cushion. The rear strip is mounted at the bottom edge of the rail.
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The front ledger strip is mounted near the top of the rail.
Wood Flooring Floor Hardwood Gas

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Upholstery complete.
Furniture Comfort Wood Outdoor furniture Flooring


Next up I will finish the ottoman, and staining won't be far behind.
Absolutely awesome! A very inspiring project. Can't hardly wait to see it finished. Great work Pinto. Bravo!
 

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Stain and Lacquer

I sprayed the chair with Rodda #19 stain, which I thin with a splash of mineral spirits.
Wood Floor Flooring Wood stain Hardwood

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After the chair had dried for 24-48 hours I sprayed Rudd lacquer (Satin sheen), which I strain and thin 20% with lacquer thinner. After the first coat I sanded with 320 grit soft sponges, and cleaned the dust with cheese cloth (not tack cloth) and compressed air.
Wood Tin Tin can Ingredient Flooring

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After the second coat I wet sanded with 1500 grit soft sponges. The whole chair only took 15-20 minutes to wet sand.
Wood Infant bed Wood stain Cradle Flooring

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The Rudd lacquer sprayed well, and left a nice satin finish without too much fuss.
Building Wood House Fixture Wood stain

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Here is the completed project page…
http://lumberjocks.com/projects/99452
Cheers!
Great finish of a very nice project. Really enjoyed this Willie.
 

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