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Hans Braul
01-24-2010, 7:45 AM
I'll start with the finished product first, then add progress pics and describe some of the challenges along the way...

The basic design was downloaded from FWW but I made a number of changes to add curves. The original had straight tapered front legs, mine are curved. I also added an outward curve in the back legs whereas the original had straight tapers. The crest rail of my chair is wider and has more curve than the original. Also I changed the floating tenon arrangement to provide deeper tenons for strength.

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John Grabowski
01-24-2010, 7:48 AM
Looks very nice...I look forward to seeing how this came together as I am going to be doing the same once I procure a new bandsaw.

Beautiful.

John G

Hans Braul
01-24-2010, 7:53 AM
Because I only had access to 1" stock I had to glue up thicker stock to provide the curves I was looking for.
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From a previous attempt I learned NOT to cut the final curves until the mortices were all cut. For strength, I used a Domino to cut the mortices and made 1-7/8" wide tenons for the leg joints instead of using standard Dominos. Then I dry-fit the (very) rough pieces to ensure everything fit before cutting the curves...
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Hans Braul
01-24-2010, 7:58 AM
Once the pieces were morticed I cut the shapes on the bandsaw...
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The backsplat is 8.5" wide so I had to rip the rough stock and cut the same curve into each piece, then glue them together for final shaping

Hans Braul
01-24-2010, 8:01 AM
I did the final shaping with planes and spokeshave but must admit I did resort to a belt sander for some of the concave surfaces where the grain wasn't cooperating. The downside of laminating my stock was that I got grain running in opposite directions and there was no "preferred" direction.
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Hans Braul
01-24-2010, 8:05 AM
The seat is 1/4" baltic birch ply with slats cut into it to allow it to flex. This is covered with foam, then fiberfill and the fabric.
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Alex Shanku
01-24-2010, 9:30 AM
Hans,

I really like that chair!

I am looking to build a set of 8, and this definitely gives me some inspiration.

Nice work.

John Grabowski
01-24-2010, 1:33 PM
Again it looks great...Can I ask what FWW plan you are referencing on this chair project?

John G

Hans Braul
01-24-2010, 5:47 PM
Again it looks great...Can I ask what FWW plan you are referencing on this chair project?

John G

The chair is designed by Matthew Teague and there is a step by step video on the FWW site (search under his name). You need to be a member to get pdf plans for the chair.