First up in the chair building process is cutting to tenth and width the wood pieces for the seats. I try to always do a 2 board seat giving the most visually pleasing grain patterns especially after grinding and shaping the seat. Now when clamping 2'' material lots of clamp pressure is required, I think I used every clamp in the shop!
Im using my cabinet scraper to remove the excess glue, you can see the cabinet makers triangle I draw on the seat blank when organizing the pieces before glue up, this help keep everything in order and glued to the piece it should be.
This will be one of the 2 cherry seats i'm doing, they are going to be beautiful not just from my work but from what nature has given up.
The seat blanks need to be trimmed to length, I do this using my "flying dutchman" or table saw sled, this is a great tool that really helps me make precision cross cuts that are easily repeatable and safe.
The riving knife which you see behind the spinning blade keeps wood that has tension in it from hitting the rear of the spinning blade, which at the rear is pulling up thus causing kickback.
Here i'm cutting out the notches in the rear corners of the seat, i'm using a miter gauge with a large fence and some clamps to hold the seat while I make the cut.
The front notches get most of the material removed on the band saw, I trim to about 1/16'' of the final notch size, then clean the joints up using a jig and a router.
Here are 4 beautiful walnut seat blanks
I now clamp my front joint jig the the seat and clean the joint to its final size using a router with a bushing that rides along the jig.
Now we are well on our way , the notches have been cut for all of the legs.
The notches then have a rabbit on the top and bottom of the joint to create a tongue which will fit into a dado groove in the legs, this is call a Maloof joint.
Starting to sculpt the seat using my Kutzall carbide grinding wheel
Cherry seat has been sculpted and sanded to 500 grit, some more shaping still need to be done at the front of the seat.
The seat above has not been carved yet, you can see the depth holes which help me carve to the depth that I want.
Pair of cherry seat blanks
4 seats and rear legs
This is a seat that has birds maple being used as the internal blank which is the exact thickness of the tongue I created, the dado in the leg is then cut to fit the tongue.
3/4'' round over on the shaper table
The dados get cleaned up with a shoulder plane to fit
The old fashion way (-:
Look a chair is born!
I forgot the glue, kidding just a pile of legs and a seat for a Cherry bar stool
Line up of 9 sculpted bar stools well on there way through the fabrication process
Initial shaping on the seat
Always nice to loose a few pounds off your legs
5/8'' round over used for initial shaping on the legs
Now you can see the form staring to take shape
Finally gluing the front legs onto the first walnut seat
I've had my morning coffee and ready to grind!
After the first session of shaping using my angle grinder and kutzall carbide grinding wheels by Oliver.
More legs more clamps
I've been busy, all the legs have now been glued to the bar stool seats
These are my tools course and medium grinding carbide grinding wheels by kutzall, I love these things very safe never catches and lasts forever!
Clamping up some leg stretchers, still lots of work to do but i'm well on the way to making some beautiful and comfortable bar stools.