Midnight Woodworking

Woodworking

Pub chairs – day five

So I went out and spent some money today. I picked up a 4-1/2″ angle grinder, a power carving disc, and a couple of flap sander discs. The bandsaw was rather inconsistent with cutting the curves in the seat pieces. I picked up these items to help me quickly carve the seat down to where I wanted it.

Evening out the seat sections

Evening out the seat sections

The power carving wheel and the sanding discs were extremely aggressive and everything was ground down to where I wanted it in about five minutes. Not a perfect surface, but impressive none the less.

All ground down

All ground down

After sanding the surface down further with my orbital sander, I made up a very crude beam compass with a piece of scrap and a nail. I marked out the 10″ radius for the rear and the 15″ radius for the front.

Laying out the curves

Laying out the curves

Next I layed out the notches for the legs.

Seat layed out

Seat layed out

Once everything was drawn, I cut it out on the bandsaw.

cutting the seat shape on the bandsaw

cutting the seat shape on the bandsaw

 

1/4" round-over

1/4″ round-over

With that done, I got out my old trim router to do the 1/4″ round-over. I needed the router with the smallest base because a wider base would straddle the curves of the seat and the bit would rise up too high.

The seat sanded down

The seat sanded down

To do the 1/8″ chamfer on the bottom, I had to get the router with a larger base because my chamfer bit was too large for the trim router.

1/8" chamfer on the bottom

1/8″ chamfer on the bottom

Next I got the seat back that I made yesterday and cut it down to 20″ wide and layed out its shape to be cut on the bandsaw.

Cutting the seat back

Cutting the seat back

After that was cut, I finish sanded both the seat and the back.

Seat and back ready for assembly

Seat and back ready for assembly

One last thing I want to do today. When I carved the seat out, I cut down into an imperfection on the walnut. This area would get picked at by the kids or get filled with dust or crumbs. I decided to fill it with a two-part epoxy. Once it dries, I can scrape it down flush. It should blend in nicely with the finish when the project is complete.

Filling the gap with epoxy

Filling the gap with epoxy

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This entry was posted on April 17, 2013 by in furniture and tagged , , , .

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