LumberJocks Woodworking Forum banner
81K views 98 replies 37 participants last post by  kaerlighedsbamsen 
Ladder Back

This is the Morris Chair I am building.

-
-
-
-
-
Well it's time to make the corbels so I cut a tongue on some 1-1/8" thick stock. The tongue is 3/4" wide to fit snugly in the leg dado.

-
-
-
-
-
Once the tongue is cut, I place the corbel blanks in a jig to trace the curved shape.

-
-
-
-
-
Here the shape of the corbel has been transferred to the blanks.

-
-
-
-
-
I rough cut the corbels at the bandsaw, cutting as close to the line as possible.

-
-
-
-
-
Next I pattern rout the corbels to final shape.
Wood Floor Flooring Aircraft Tool

-
-
-
-
-
I avoid routing the end grain section of the corbel, because it can cause chipout. I prefer to sand the narrow end of the corbel to final shape.
Wood Tool Wood stain Hardwood Flooring

-
-
-
-
-
Chamfering the diamond shape on the front legs is pretty easy. Just tilt the table to 15 degrees and sand to your line. Chamfering the rear legs is a bit more challenging because of the angle. To chamfer the back of the rear leg set the table angle to 22 degrees (miter gauge at 90 degrees). To chamfer the front of the rear legs set the table angle to 8 degrees (miter gauge at 90 degrees). To chamfer the sides of the rear legs set the table angle to 15 degrees (miter gauge +7 degrees on one side, and -7 degrees on the other side).
Wood Gas Engineering Machine Hardwood

-
-
-
-
-
The settings above work for a chair that has armrests angled to 7 degrees. Adjust accordingly if your plan calls for a different angle.
Table Wood Rectangle Wood stain Hardwood

-
-
-
-
-
Side assembly glueup.
Wood Gas Engineering Composite material Hardwood

-
-
-
-
-
Side assembly complete.
Wood Wood stain House Hardwood Flooring

-
-
-
-
-
Tenons chamfered to final shape at the oscillating belt sander.
Wood Wood stain Flooring Floor Hardwood

-
-
-
-
-
Here you can see how the chamfered diamond follows the angle of the armrest.

-
-
-
-
-
Now I turn my attention to the ladder back assembly. Instead of laminating strips for the curved backslats, I cut them from solid 8/4 stock. This way I can use a dado blade to establish offset tenons before I cut the curved shape. Another option is to use flat back slats with no curve at all.

-
-
-
-
-
I put my oscillating belt sander to work again sanding the slats to my layout line. I start with 36 grit, and work up through 120 grit.

-
-
-
-
-
I sand the parts with a ROS to 150 grit, and fine tune the tenon fit with a sanding block.

-
-
-
-
-
I run the slats through the router table on edge to ease the sharp corners.

-
-
-
-
-
Ladder back glueup.

-
-
-
-
-
I use a sled at the tablesaw to make the angled cut on the armrests.

-
-
-
-
-
Run the armrest through the router table on edge. This way the router bearing won't dive into the holes drilled in your armrest, and bobble the cut.

-
-
-
-
-
Well, that's it for this entry. Next up will be fitting the corbels, and making pegs & washers for the backrest adjustment mechanism
Looks like she's coming along great! Looking forward to the next installment!
 

Attachments

Corbels, Pegs, and Washers

With the two side assemblies glued together, I can now check the fit of the ladder back.

-
-
-
-
-
Once you get the armrests fit, everything else seems to come pretty easy on this project.

-
-
-
-
-
Here is a look at the beveled through tenons in the armrest.

-
-
-
-
-
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.

-
-
-
-
-
Now I set out to make the 4 pegs that secure the backrest.

-
-
-
-
-
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.

-
-
-
-
-
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.

-
-
-
-
-
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.

-
-
-
-
-
In the last episode we cut the corbels to shape. Now the corbels are glued in place.

-
-

-
-
-
-
-
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.

-
-
-
-
-
Next I laminate some leg stock for the ottoman.


Next up will be the ottoman build.
Cheers!
You're just about there! Am interested to see how you finish the chair. I just finished my Morris chair, and am curious to see your finishing choice.
 

Attachments

Leather Upholstery

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

-
-
-
-
-
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

-
-
-
-
-
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

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

-
-
-
-
-
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

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

-
-
-
-
-
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

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

-
-
-
-
-
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

-
-
-
-
-
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

-
-
-
-
-
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

-
-
-
-
-
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

-
-
-
-
-
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

-
-
-
-
-
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

-
-
-
-
-
Cambric nonwoven fabric is added to the underside as a dust cover.
Couch Wood Rectangle Flooring Hardwood

-
-
-
-
-
Seat cushion complete.
Comfort Couch Wood Rectangle Flooring

-
-
-
-
-
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.
Rectangle Table Wood Coffee table Gas

-
-
-
-
-
Trim the excess batting, and the ottoman cushion is ready for leather.
Comfort Fawn Linens Companion dog Wood

-
-
-
-
-
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.
Brown Textile Sleeve Rectangle Bag

-
-
-
-
-
-
Excess leather is trimmed away.
Furniture Wood Orange Rectangle Recipe

-
-
-
-
-
Cambric dust fabric is applied, just as with the seat cushion.
Wood Rectangle Floor Gas Hardwood

-
-
-
-
-
Ottoman cushion complete.
Brown Comfort Rectangle Auto part Automotive design

-
-
-
-
-
Now we can move on to the backrest cushion.
Wood Art Artisan Table Bag

-
-
-
-
-
Here I am sewing the welting (piping) at the class. I used 3/16" welting cord.
Automotive design Table Engineering Wood Eyewear

-
-
-
-
-
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

-
-
-
-
-
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.
Brown Bag Beige Khaki Sleeve

-
-
-
-
-
Here the backrest cushion has been sewn.
Brown Rectangle Material property Sleeve Bag

-
-
-
-
-
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.
Brown Sleeve Orange Bag Collar

-
-
-
-
-
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

-
-
-
-
-
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).
Neck Waist Thigh Material property Abdomen

-
-
-
-
-
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

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

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

-
-
-
-
-
The backrest cushion slides easily into the leather cover.
Brown Orange Rectangle Comfort Wood

-
-
-
-
-
Backrest cushion complete.
Brown Wood Flooring Bag Comfort

-
-
-
-
-
Finally I can install the ledger strips that support the seat cushion. The rear strip is mounted at the bottom edge of the rail.
Brown Wood Rectangle Flooring Floor

-
-
-
-
-
The front ledger strip is mounted near the top of the rail.
Wood Flooring Floor Hardwood Gas

-
-
-
-
-
Upholstery complete.
Furniture Comfort Wood Outdoor furniture Flooring


Next up I will finish the ottoman, and staining won't be far behind.
Another great blog! Looking forward to seeing the finished set!
 

Attachments

Leather Upholstery

I took a leather sewing class to learn how to make the Morris chair cushions.

-
-
-
-
-
The seat cushion and the ottoman cushion require web frames. Here I am milling the half-lap components for the web frames.

-
-
-
-
-
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.

-
-
-
-
-
Corner blocks are added to the large seat cushion for additional strength.

-
-
-
-
-
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.

-
-
-
-
-
I stretch nylon webbing over the frame, and secure it with upholstery tacks.

-
-
-
-
-
I use #10 or #12 tacks to attach the straps. An occasional staple helps the webbing lie flat.

-
-
-
-
-
Seat cushion webbing complete. Notice how the straps are woven together.

-
-
-
-
-
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.

-
-
-
-
-
This is the underside of the ottoman frame. Notice how the corners are knocked off so it will fit inside the ottoman legs.

-
-
-
-
-
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.

-
-
-
-
-
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.

-
-
-
-
-
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.

-
-
-
-
-
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).

-
-
-
-
-
Cambric nonwoven fabric is added to the underside as a dust cover.

-
-
-
-
-
Seat cushion complete.

-
-
-
-
-
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.

-
-
-
-
-
Trim the excess batting, and the ottoman cushion is ready for leather.

-
-
-
-
-
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.

-
-
-
-
-
-
Excess leather is trimmed away.

-
-
-
-
-
Cambric dust fabric is applied, just as with the seat cushion.

-
-
-
-
-
Ottoman cushion complete.

-
-
-
-
-
Now we can move on to the backrest cushion.

-
-
-
-
-
Here I am sewing the welting (piping) at the class. I used 3/16" welting cord.

-
-
-
-
-
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.

-
-
-
-
-
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.

-
-
-
-
-
Here the backrest cushion has been sewn.

-
-
-
-
-
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.

-
-
-
-
-
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.

-
-
-
-
-
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).

-
-
-
-
-
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.

-
-
-
-
-
Next I blind stitched a slip cover, and placed it over the backrest cushion.

-
-
-
-
-
This will help the leather slide over the cushion more easily.

-
-
-
-
-
The backrest cushion slides easily into the leather cover.

-
-
-
-
-
Backrest cushion complete.

-
-
-
-
-
Finally I can install the ledger strips that support the seat cushion. The rear strip is mounted at the bottom edge of the rail.

-
-
-
-
-
The front ledger strip is mounted near the top of the rail.

-
-
-
-
-
Upholstery complete.


Next up I will finish the ottoman, and staining won't be far behind.
Willie, I had the same thought process as you regarding the webbing, but made the opposite decision. My upholsterer told me that the webbing would be much more expensive, and that I wouldn't be able to tell the difference between it and a plywood base. When I sat on the bare foam, on the plywood base at their shop, it felt very comfortable to me. I ended up using foam that is 6" thick, so that probably makes the difference. Thinner foam may require the webbing.
 

Attachments

Ottoman

Here I am building a small ottoman to compliment the Morris Chair.
Wood Rectangle Wood stain Hardwood Gas

-
-
-
-
-
The ottoman legs were laminated with thin veneers. As with the chair, I used 1/4" thick veneer strips that are later planed down to 3/32" thickness.
Wood Floor Flooring Wood stain Hardwood

-
-
-
-
-
The ottoman legs are planed to their final size of 1-3/4" square, and mortised to receive 1/2" thick tenons.
Wood Rectangle Wood stain Hardwood Natural material

-
-
-
-
-
I do an initial assembly to see how the joints fit. Everything is scaled down on the ottoman, compared to the Morris chair. The rails are 7/8" thick (vs. 1" thick on the chair), the legs are 1-3/4" (vs. 2-3/8" on the chair), and the mortises are 1/2" wide (vs. 5/8" on the chair). It seems like the ottoman is nearly complete at this stage, but there are still 16 more mortises to cut.
Wood Hardwood Wood stain Rectangle Plank

-
-
-
-
-
Mortising for the side slats. These mortises are made with the 5/16" chisel.
Wood Bumper Tool Gas Automotive exterior

-
-
-
-
-
I cut the tenons to size, checking the fit on the OUTSIDE of the mortise. Once all the joinery is done, the curves can be cut at the bandsaw.
Wood Sewing machine Sewing Floor Table saws

-
-
-
-
-
One more dry assembly lets me take a true measurement for the lower cross rails.
Wood Rectangle Wood stain Stairs Hardwood

-
-
-
-
-
The top rails are haunched where they intersect. This gives the shorter tenon as much surface area for glue as possible.
Wood Floor Wood stain Flooring Rectangle

-
-
-
-
-
I try to rip all my stock for a project at the same time. That way I minimize the number of times I have to install the dado blade. Here I am doing the finish sanding prior to assembly.
Wood Gas Hardwood Flooring Machine

-
-
-
-
-
Then the side assemblies go together.
Table Wood Flooring Floor Wood stain

-
-
-
-
-
The lower cross rails are just large enough to add some rigidity to the frame, but small enough to be out of the way when tucking your feet under the ottoman.
Wood Creative arts Wooden block Wood stain Hardwood

-
-
-
-
-
-
Once the side assemblies go together, it's just about done.
Product Wood Creative arts Wood stain Floor

-
-
-
-
-
A few more pegs to flush trim, a little detail sanding, and I will be ready to apply the finish.
Building sets Wood Toy Red Construction set toy

-
-
-
-
-
Next up will be stain and lacquer.
Wood Rectangle Wood stain Hardwood Gas
You're really gett'n the hang of this! Look'n good!
 

Attachments

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

-
-
-
-
-
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

-
-
-
-
-
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

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

-
-
-
-
-
Here is the completed project page…
http://lumberjocks.com/projects/99452
Cheers!
Thanks for posting you blog series on this project. It was really enjoyable to see the progress from a pile of lumber to this, the finished furniture!
 

Attachments

This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top