The journey of a new project.

[Derek Cohen]

I am interested to know how others plan their projects, and about the interesting discoveries they make along the way.


For the past month or 6 weeks, I have been accumulating information about Wegner's "The Chair".


I plan on building this ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/TasmanianBlackwood_zpsdb14422a.jpg


... but with this seat ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/Wegner2_zpsce998d98.jpeg


Usually I create a basic plan consisting of a few dimensions, with the image and details locked inside my head, decide on the build sequence, and then just start working.


This time it is different. For a start I am copying a famous chair and the details are important. Never mind that I do not have one at hand to measure and work from, but I have not actually seen The Chair in the flesh. I've been fortunate to obtain several important measurements, which have enabled me to draw up full size plans ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/5_zps0dc2b746.jpg


Measurements have become important as the drawings unfold a picture of complex curves built from solid wood, and the realisation that bigger chunks of timber are necessary than I had imagined at the start. I needed 6" x 6" posts.


I went looking for wood ... and met Derek The Timber Bloke (http://www.thetimberbloke.com.au/). Yes, another Derek. Derek (the other one) flies helicopters in his day job and spends his spare time and weekends salvaging urban trees. He stores, resaws, and sells some very exotic West Australian timbers. I called Derek, and he said that all he had was 13 feet (4m) of fiddleback (curly) Jarrah in this size that was from the same tree, dry and ready to go.


I must admit that I had mixed feelings. I had recently completed a kist in curly Marri, and it was a real bear to work - not just because the wood was hard, but because there is the added complexity of matching the direction of the curl as well as the colour of the wood and the grain. I really wanted to get on with the build, and so I decided to have a look at it. Anyway, I had not visited Derek before, and this was a good excuse. How many of us need an excuse to look over a new wood supplier. And just 30 minutes from my home.


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/1_zpsc635822b.jpg


The storage was impressive. This was just one of two warehouses ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/2_zps340d9dd6.jpg


Derek The Timber Bloke (no, not me) ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/3_zpsef16a4a4.jpg


I bought the curly Jarrah. Derek gave it to me quite cheaply ($150) as there was a good deal of checking and it would be necessary to saw around this. I guess that is somewhat expected with 6" x 6". I loaded it into my wife's Golf, feeling shocked at the incredible weight of each section, and wondering how I was going to manage this in my shop.


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/4_zps6b5e1704.jpg


About two weeks have passed while I plotted and planned. Today I began sawing the timber. This represents the 4 legs and the 4 rails.


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/6_zps5f669693.jpg


My plan is to build the lower section of the chair first. The chair back and arms will be easier to size and position this way. Onward to the lathe ...


Any thoughts or stories of your own?


Regards from Perth


Derek

[Jim Koepke]

I am interested to know how others plan their projects, and about the interesting discoveries they make along the way.

Interesting account so far, will watch for the rest.

Often my planing is like yours, get out the pencil and paper. If it is bigger than can be done on an A sized sheet then out come the drafting board and tools.

Currently my lumber yard is my fire wood pile and what ever is laying around the shop. There are a few local sawyers that may have things to my liking. There are the borgs in town and a couple of lumber dealers. If anything is wanted out of the norm it is a bit of a trip. But then there are some good choices a little south of here and even more if I feel like driving into Oregon.

I am beginning to like working with alder. Keeps me warm working it or burning it.

jtk

[Harold Burrell]

Wow...cool...I look forward to the rest of this!

[Jeff Wittrock]

Usually I create a basic plan consisting of a few dimensions, with the image and details locked inside my head, decide on the build sequence, and then just start working.
....


Derek,

It looks like you have very fun project underway and one that requires detailed planning. I have always admired "The Chair", and I look forward to seeing things as they progress.

I have to admit that I often shy away from projects that require that kind of detail. Maybe I'm just undisciplined, or just so tired of the detailed planning that is required in my paying job, that I simply don't have the patience to sit down and formulate a detailed plan.

I really enjoy projects where I just have a rough idea in my head and let things kind of evolve as I go and for better or worse, this method of planning often shows through in the end result.

Jeff

[Alan Wright]

I find that woodworking is hard enough.... The Stickley factory is about 10 miles from my house, and since most of my project are "mission furniture", I go to the factory store and take measurements. They are very cool about letting me take measurements and tons and tons of pics. I draw up plans and print out about 20 pics, which I tape us in my shop. Then I go to work. I spend a lot of time looking at my pictures as I build, so I know exactly how Stickley does it. Sometimes I tweak a joint or two, but I try hard to keep the dimensions constant. I find that the subtle beauty of Stickley furniture is often hidden in the specific dimensions of their designs. I've built some projects by the "seat of my pants" but I like working from detailed plans much better.

[Sean Hughto]

I personally don't like building from detailed plans - or verbatim making copies of other people's stuff. I guess I'm a frustrated sculptor/artist - I really enjoy the shaping and fitting that happens as in-the-round and in progress - stuff I never would have thought of or come to on paper. We must each follow our bliss! Nice timbers and a nice chair design, Derek!

[Jim Koepke]

I personally don't like building from detailed plans - or verbatim making copies of other people's stuff.

Most times when mine get drawing/planning it is just to determine the order of processes or to determine how to layout a joint.

Most of the time "detailed" plans are not drawn.

Many of my drawings would look like scribbles to someone else. Often they look like scribbles to me after a few years.

jtk

[Andrew Hughes]

I would start with a drawing then build with popler to work out and refine my technique.
Has anyone seen the movie the patriot with Mel Gibson at the beginning he's making a chair and next to him is abig pile of broken ones.That would be me.Kinda like my first job doing crown molding:eek:
The curly Marri looks great!

[Christopher Charles]

Hello Derek,

Looking forward to following, nice score on the Marri! I have yet to develop a set of full scale drawings but have also not tried to reproduce a piece, and would likely do a full design if I ever do so.

If you haven't found it already, Caleb James's blog may be of interest as he has considerable detail on weaving seats for Wegner chairs (can't remember if this was already mentioned in you previous post):

http://kapeldesigns.blogspot.com/

Cheers,
C

[Derek Cohen]

I personally don't like building from detailed plans - or verbatim making copies of other people's stuff. I guess I'm a frustrated sculptor/artist - I really enjoy the shaping and fitting that happens as in-the-round and in progress - stuff I never would have thought of or come to on paper. We must each follow our bliss! Nice timbers and a nice chair design, Derek!

Hi Sean

I feel the same way as you. I have never built anything from a plan, ever. I doubt I ever will. I know that what will eventuate will still be Wegner-inspired, that it cannot be an exact copy, and that it will be an interpretation at best. I am OK with that. The curves on the chair will reflect how I believe a curve should flow, because I will be the one spokeshaving it, but the design does still need to attempt to be true to Wegner's original view since this is what I am paying homage to.

Regards from Perth

Derek

[Derek Cohen]

If you haven't found it already, Caleb James's blog may be of interest as he has considerable detail on weaving seats for Wegner chairs (can't remember if this was already mentioned in you previous post):

Hi Christopher

I did contact Caleb. He has not build The Chair. However, he has done a few nice videos of weaving Danish Cord, which have taught me what to do for the seat.

Regards from Perth

Derek

[Don Jarvie]

I use a full size drawing mostly to get the proportions right. This way you can tweak the measurements before you cut. A cutlist can be made then. The drawing also helps when you need to adjust the size of one if the parts you can see how it will effect the final piece.

[Derek Cohen]

Here is a little cross post from Wood Central which I think some here will find interesting.

What I like about the work of Wegner and Maloof is their use of sweeping lines. However there is a flow in The Chair and the Maloof rockers that does not work well in the Maloof chair. It just seems a little busy to me. I had been considering building one for a few years, and even purchased plans.


I envisage building The Chair in a way similar to the methods used by Maloof. Some of it is best done with power tools, such as a router for the mortices and a bandsaw for the rough shaping. Then it will be spokeshaves and scrapers.


The measurements and templates I am building will help get close. And then it is by eye.


Tracing the drawings onto templates ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/7_zps00d5c776.jpg


Just to show the templates. Which would you saw first, the top or the bottom?


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/8_zpsc64be079.jpg

I was advised:


Cut and fit your joinery first, while you still have reference surfaces.

Cut the concave faces first, because your offcuts will come off in one piece, instead of several. Then tape them back onto your stock (using 3M blue painter's tape, but you knew that) to provide support and reference faces for subsequent cuts, and also to preserve the marks you made from the pattern.

Maloof's bandsaw carving: http://www.youtube.com/watch?v=l272IFKogHU

Using the bandsaw the way Sam Maloof did is something I just shake my head at. My Hammer 4400 scares me at times as it is so powerful that an unsupported board can be (has been!) ripped out of my hands. A thinner blade than I usually use - 1/4" rather than 1/2" - may help. Sam's looks like 1/4".

The issue of joinery first or later is one that I have been thinking about for some time.

The given for most joinery is to work/mark from a reference side. The joinery here is (1) mortices in the round legs and arms, (2) tenons on the stretches, and (3) finger joints on the chair back/arms.

The mortices on the legs will be cut after the legs are turned. I could do this before (have done this in the past), but I am concerned the wood will chip out too much even with the mortice plugged with a filler piece. Further, there are intersecting mortices, and these are not at right angles. In fact I will only be sure of the second angle when there are parts to fit together.

The reason for a router for the mortices is that the tenons are haunched, that is, the mortices will have two depths each. That is difficult to chop accurately. Of course I could use a different joint, but I did want to explore what Wegner designed.

Here is the mortice and tenon joinery used on The Chair (stills taken from the video):


Tenon ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/12_zps8e65dbbf.jpg


Mortice ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/13_zps56b36ea9.jpg


Tenon into mortice ...


http://i13.photobucket.com/albums/a262/Derek50/Furniture/The%20Chair/14_zpsea2952ea.jpg


Regards from Perth

Derek

[Derek Cohen]

Today I won an auction for an original Wegner The Chair. These were made under license in Australia for a short while in the 1960's. The price was low, so I am feeling quite pleased. This is a solid seat, in Tasmanian Blackwood and Teak.


I am going to put any sawing on hold until it arrives so I can check the measurements I have. It is on the other side of Oz, and will take a few weeks to get here (I have to arrange shipping).


Now I will have a proper model to compare to. That should make a very big difference. Importantly, I shall have the seating to explore first hand.


Regards from Perth


Derek

[Zach Dillinger]

Today I won an auction for an original Wegner The Chair. These were made under license in Australia for a short while in the 1960's. The price was low, so I am feeling quite pleased. This is a solid seat, in Tasmanian Blackwood and Teak.


I am going to put any sawing on hold until it arrives so I can check the measurements I have. It is on the other side of Oz, and will take a few weeks to get here (I have to arrange shipping).


Now I will have a proper model to compare to. That should make a very big difference. Importantly, I shall have the seating to explore first hand.


Regards from Perth


Derek

Great news Derek! You'll be able to really knock your chair out of the park.

[Derek Cohen]

Thanks Zack.

Regards from Perth

Derek

[Gary Muto]

Derek,

This is an exciting project. I look forward to following it... while I continue to look for a new home and shop.

[Adam Cruea]

I hope it turns out just as you hope, Derek. I'm sure it will, though.

And for the record, I can't work from plans. I have to have everything in my head. My wife shows me a picture with something of known size for reference usually and I can go from that. As an example, she showed me a bench and chairs her grandfather had made, gave me a reference size from her memory, and I worked from that.

It's just very hard for me to work from plans. I can follow instructions quite well, but just plans, and I'll be scratching my head for a very long time. However, I can come up with the instructions and plans in my head just fine; getting them to written form is impossible though (and I've tried). Highly frustrating for my wife when she wants me to make something for her because she has to trust we have the same vision.