Well, the seats are all glued up. I pulled the clamps and, as I suspected, the cauls were stuck to the seat. Just a quick tap with the hammer and they fell off with no problems. I flipped the seats over to clean up the bottoms so I had a flat surface to work from. Once again, the card scraper seems to do the best job of cleaning up the glue squeeze-out.
With the back cleaned, I move on to laying out the seats. With the extra inch or so on either side, the layout was a bit more difficult than the first seat. I started that one with the seat boards cut to length so I had four straight, square sides to start with. With these, I determined the rough center of the seat and drew a reference line. I stated by laying out my arcs with a crude beam compass. It is just a stick with three holes drilled in it. I poke a finish nail through the pivot hole and my pencil through the holes at 10″ and 15″ to swing the arc. Nothing fancy, but it works well.
With the arcs drawn, I clamped a straight board to the center line and laid out my notches and flat sides with two squares.
With that done, I had to cut out the seats. I could have cut the flat sides on the band saw, but they would have been slightly wavy. I thought this would be a perfect opportunity to use the new saw. It will cut 14″ at 90 degrees, so I clamped it in and tried it. It cut a few inches past my straight portion of the seat, giving me two perfectly parallel sides. The clamp is pretty cheesy, but everything else worked perfectly.
I finished the rest of the cuts up on the bandsaw. The notches are a pain, and I am sure there are better ways to cut them, but with a little patience, I had everything cut and ready for sanding.
I didn’t have as much to take down on these seats as I did on the prototype, so I used the 120 grit flap sander on the angle grinder. It may be still a bit more aggressive than I needed, but it did the job. The grinder sure makes one heck of a mess though. I will be doing a lot of vacuuming tomorrow when all the dust finally settles. With the seams leveled out, I broke out the orbital sander. It does seem that using the clamping cauls brought the boards into better alignment than the prototype, but there is still a little up and down. Oh well, I like it better that way anyway.