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LEGS:
Bottom Compound Cut -
Angle: 74.4 degrees
Splay: 7 degrees
Top Compound Cut -
Angle 41.2 degrees
Splay: 7 degrees
ARCHES:
Leg Joint -
Angle: 48.8 degrees
Arch Joint -
Angle: 64.4 degrees
BRACKETS:
Compound Cuts -
Angle: 64.4 degrees
Splay: 7.4 degrees
Total height rear - 6"
Total height front - 2"
Music Credits:
Tell Me Should I have Know
Victor Lundberg
player.epidemicsound.com/
Venetian Blinds
Mattias Tell
player.epidemicsound.com/
Leaving the Main Road
Dawn, Dawn, Dawn
player.epidemicsound.com/
** TRANSCRIPT OF VOICEOVER**
How to make, or how I made, this mix-medium chair.
Let’s get into it
I started by squaring the lumber with the jointer, planer and table saw
Then, ripped 2x2” pieces to start in on the leg frames
After somehow knocking the camera lens to manual focus instead of auto focus, I then took the 2x2”s to the miter saw and cut compound miters to account for the leg set angle and splay. I’ll list the exact angles in the description below.
Each leg set had two 15 7/16 ”inch pieces (at the longest diagonal ) to create the legs, and two 5 7/16” inch pieces to create the arch that would connect the legs as well as the set to the rest of the chair.
After completing the cuts, I used a domino jointer to connect one arch and one leg together.
Then, used some counter angle clamping to glue the 4 sets together.
After that, I took two of the pairs and again used the domino jointer to join them together to create a pair of legs for the front and back of the chair.
With those complete, I used a 45 degree chamfer bit to add a bevel to the outer edges of each set.
Then it was time to clear some space for the steel plate that would anchor the metal bracketing to the legs
Happy with the fit, I turned to drilling the recesses for the lag screws.
Then got to work cutting the steel tubing to form the metal framework.
I’ll again include the compound miters used to create these pieces in the description below.
With the tubing cut, I prepped each piece by grinding bevels along the pieces I would butt weld together.
And tidied up the plates as well.
To make the rear bracketing, I tack welded the long uprights to the plate steel. As well as the smaller tubing pieces two inches above the plate along the long upright.
Then ran my welds.
And ground the beads flush
I worked through the same process for the shorter front braking system. Finishing off the the pieces with a second piece of plate steel on top to complete the connection points.
With the bracket basics done, I used the plate steel as my guide to mark the pre drill recesses for the lag bolts.
Then, test fit the brackets
Happy with the mounting, I finished off the rear brackets by welding the final plates to the smaller bracket and top of the longer upright to connect to the seat and back respectively
Then, cracked on with the seat - first by squaring the lumber
Then laminating enough for a roughly 18 x 16”
Once that cured, I cut the seat panel square.
Then, with the table saw set to 50 degrees, cut a bevel on both of the sides.
Of course I slight miscalculated in order for the blade to remove the excess entirely, so I used the table saw and cross cut sled to remove the bevel, and tidied up the seam with a hand plane.
Then, I mapped out and began hand carving a more comfortable seat
Pleased with the slope of the seat, I decided to create a more interesting shape by cutting down either side of the seat.
With the seat roughed out, I got to work measuring, marking and cutting away the recesses for the plate of the metal brackets ant would anchor the back of the seat to the back leg set.
Then, test mounted it into place.
I went about the same steps to place the front leg sets.
Pleased with that, I knew I would need to add more rigidity toward the base of the legs. So I got to work on the metal bracket that would act as the chair’s stretcher.
Giving the plate steel panels the same recess treatment
Before turning to welding the actual frame together.
Then grinding away my sloppy welds
To finalize this stretcher system, I rounded over the ends of the plate steel to ensure the mounts would fit nicely on the beveled legs
Then got to work placing the recesses for the lag bolts
And of course - test fitting for success.
The final piece of the puzzle was the back - honestly, I went through a few ideas before landing on simply hand carving the curved back. I’m still not super stoked with this final option - but that’s the beauty of chairs, they give you a great platform to mess around with design. They have to look good from so many angles, I learn so much every time I attempt to put to reality one I’ve designed a facet of in my head.