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Thread: The Great Morris Chair project

  1. #196
    Join Date
    Oct 2006
    Location
    Windsor, ON
    Posts
    657
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    3

    Wink over the hills and far away

    Good Day to the Creek,
    For those keeping score at home, this is the third time I use my arch offcuts in assembly.
    If you want to use parallel clamps, I suggest you keep them in one piece, and keep them handy.
    handy-offcuts.jpg handy-blue-tape.jpg
    -used as cauls to glue side slat tenons pinched between rails
    -taped to crosscut sled as ramp to trim and square arm bent lams
    -as clamping cauls to attach bow arms onto sides

    Yes, they look similar to my dry fit pics...
    but now there is an actual glued woodjoint to show.
    I put another 2 hours into each side, for painstakingly tuning the arch joint, handplaned foot and tenon chamfers and fussy glue-up.
    Many dry fits took patience, but anything less than tight and tidy arch joints would have bothered me for decades. (as would wood filler)
    right-arch-joint.jpg left-arch-joint.jpg

    Both sides of the story. I am glad to be over the Big Hurdle! whew
    both-sides-of-the-story.jpg

    Still with us? Thanks for lookin'
    W

    *Bonus trivia question: I will buy a Coke for the first Creeker to post which
    band did the song in my post title. (hey, no googling)
    Last edited by Walt Caza; 10-26-2008 at 11:58 AM.
    There are no shortcuts to anywhere worth going! WCC

    Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind - Dr. Seuss

    Crohn's takes guts. WCC

  2. #197
    Join Date
    Feb 2008
    Location
    Stanwood, WA
    Posts
    3,059
    Quote Originally Posted by Walt Caza View Post

    *Bonus trivia question: I will buy a Coke for the first Creeker to post which
    band did the song in my post title. (hey, no googling)
    Led Zeppelin
    Dewey

    "Everything is better with Inlay or Marquetry!"


  3. #198
    Join Date
    Mar 2006
    Location
    SoCal
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    Things are really coming along. I have been remiss about posting here. I contribute that to my disappointment about not being able to join in due to some conflicts. I think the whole idea of going through this together is great and hope to join Walt on a future build. Keep up the great work. I better get my current effort brought to ground and move on.
    "A hen is only an egg's way of making another egg".


    – Samuel Butler

  4. #199
    Join Date
    Jul 2003
    Location
    Rochester, NY
    Posts
    4,717
    Seeing all these QSWO chairs is giving me an itch I can't scratch! I must confess that I had lost track of this thread and haven't paid much attention, but they sure look great though. Nice progress by several of you!
    Happiness is like wetting your pants...everyone can see it, but only you can feel the warmth....

  5. #200
    Join Date
    Oct 2006
    Location
    Windsor, ON
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    3

    Red face truly nearly blew it (pic)

    Hello Everyone,
    Not much shop time this week. I did manage to glue my stretchers.
    It took less than an hour...but what an hour it was...

    Usually, before a critical glue-up, I prepare to do it.
    Take the clamps down off the wall, and open the jaws wide.
    Glue ready. Tape off to protect where the bars might harm sanded parts.
    Catcher cardboard underneath, to protect cast iron flat reference surface.(my saw)
    Skew chisels ready to winkle away squeeze-out. Assembly mallet.
    A couple folded and moistened paper towels, to try and keep hands clean(ish).
    Cauls ready. Note the starting time for complicated glueups.( gotta beat the clock!)

    For tricky assembly, I sometimes even do a little 'skull' practice.
    That is to say, a mental walkthru of the glue hustle dance steps before starting.
    Normally I make a huge effort to get my shot together.

    But this time.......
    Somehow all that went out the window, and cold air rushed in!
    So after work, I ran enough shop heat to apply white glue.
    I have bought, and been using white glue on this chair project, due to the longer open time. (I'm a yellow man)
    I did just read, however, that white PVA is not quite as strong as yellow. I hope that's not true!
    I was under the impression that they were comparable, except for open time. uggh

    Knowing my stretchers had been fitted back at the end of August, I just went casually ahead.
    I smeared glue up to 1/2" away from the ends of all four thru tenons.
    No big deal, I inserted them all they would go, which was just a little, and started clamping to drive them in.
    Well, the length of those tenons exceeds the jaw range of parallel clamps, costing time.
    Compounded by the fact that I wasted time running around doing all the things I should have done before starting.

    I forgot to check the clock, But I was sure it was beyond 20 minutes(ish)!
    I was still searching high and low for paper towels to wipe my hands.
    (I considered sacrificing my pet Rush shirt I was wearing. mm)
    The joints were not closed. Tick Tock.
    Much to my chagrin, the joints would not close.
    A nice snug fit, plus glue= panic. (in my excited voice) That's bad math!!
    As I realize my predicament, I know that I could scrap my chair right here, right now. (and for an audience too!)
    Sam Maloof said to leave room for glue. Good tip.

    I scamble to locate my soft faced dead blow hammer.
    It has been my pet persuader since my machine shop days as a kid.
    In a flurry of mad swings, tick tock, I coax this side a little.
    In ever-more-excited whaps, I get that side to move a hair.

    I had to keep the side frames pretty parallel, or the racking just seized the show.
    I took it all too lightly. Skipped my prep routine.
    My head was already at dinner. Did not have my persuader handy.
    Flirted with a mini-disaster. Receded my hairline ever further.
    But finally got them to close. I was drained and panting by the time it was over.

    Funny how quick the shop can humble us.
    Mad at myself, for having fussed so many details thus far, and then
    fumbling and fudging final frame assembly. (quadruple f score)

    My tail may be between my legs, but my chair stands upright now!
    What a jack...um..er... donkey.
    w

    streeetchers.jpg

    ps I damaged a pair of leg veneers in my frantic hammer smashing. fudge
    It's hard to hammer around all those corners... splintered mess
    Last edited by Walt Caza; 10-30-2008 at 5:31 PM. Reason: tweak
    There are no shortcuts to anywhere worth going! WCC

    Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind - Dr. Seuss

    Crohn's takes guts. WCC

  6. #201
    Join Date
    Dec 2006
    Location
    Toronto Ontario
    Posts
    11,248
    Hi, I've attached some photo's of the chairs I built 7 years ago.

    The back slats on the chairs are steam bent, and are 3/8" thick.

    Diann did the upholstery work for me.

    The finish is two coats of Watco Dark Walnut Danish Oil, followed by one coat of LV Polymerizerized Tung Oil sealer, then 4 coats of Polymerized Tung Oil/Sealer mixed 50/50.

    Then a couple of applications of wax.

    My kids call them lawn chairs........Regards, Rod.
    Attached Images Attached Images

  7. #202

    Not for Everyone

    I realize that this is probably not what either Morris or Stickley had in mind when they designed their chairs. But if they hear my explanation I think they will understand. I do know that Morris’ intent was to provide a comfortable place for the middle class workers of 19th century to rest at the end of the day. This is a gift to my brother for his generosity in sharing his NE Patriots season tickets. He is definitely middle class and works hard. This chair will be in a room that is really a Patriots shrine and any other colors would look out of place (it also works well for the Red Sox). He originally wanted the spindle version that the group was building, but the original Stickley 1906 version grew on him and he changed his mind. He chose to have it made out of ash (he saw it on our ash entertainment center, but he also liked the baseball bat link). The finish is Bush Oil and maintains the Stickley preferred satin finish. The cushions are faux leather (I really needed these colors). They were professionally done for $275 plus fabric (about $100).

    Congratulations to the group: the chairs all look like they have crossed or are approaching the finish line in great shape. My only regret is that I didn’t get to build the “group” spindle version. I did however enjoy following the group build, and would participate in another for the right project but I have no idea what that might be.

    Walt and Gary; you should be justifiably proud with what you started and pleased with the results.
    Attached Images Attached Images

  8. #203
    Join Date
    Oct 2006
    Location
    Windsor, ON
    Posts
    657
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    3

    Smile ...passing the torch

    Hi All,
    We have a winner ..... Dewey won the trivia contest!
    I look forward to sharing a sodapop with you sometime.(just gotta figure out how)

    Thanks to Glenn B., Scott S., and David F. for your generous kind words.
    We did not do this thing for applause, but it is warming to receive!
    It has been fun, but it takes time to snap and post pics and details.

    Thanks to Rod S. for posting his pair of highly figured oak Morris chairs.
    It's great to see some variety in design, and amusing to hear them referred
    to as 'lawnchairs'. Thanks for throwing-in a bonus finish schedule to boot!
    You will be mentioned when I do the honourary Morris builder list.

    Thanks for another terrific chair by David F.
    It cannot be denied you have captured the spirit of the A&C movement.
    Your Stickley design is a special gift that will keep giving for decades!
    I dig those plump corbels, and a nice story of generousity back and forth.

    My own chair is nearing the homestretch. I will soon post my corbels and seat cleats.
    Time for me to start considering colours and upholstery options.

    ***
    Fair warning to anyone who may have felt they 'missed the bus'.
    While we have encouraged builders to do their own thing, at their own pace...
    I have it from a pretty reliable source that Dewey is pulling his shop together, and aiming to begin his Morris chair soon.

    Maybe others would like to start around the same time?
    As we saw from Dewey's excellent inlay tutorial, his pics and posts are top notch.
    Anyone wanna catch the next wave with him?

    As we have blazed a trail, demonstrating that a group build is possible and rewarding, I have tried to steer the ship.
    I know I have been longwinded, but I wanted to tell the story, and I knew that anyone could skim it or skip it at will.
    I have tried to be the glue guy, to keep us rolling.

    Gary and I want to thank the Creek for the support, and the bandwidth!
    Creekers are pic hungry, and we offered what we could...
    but over 20000 views exceeds all expectations, and shows super support.

    Special thanks to Nathan.
    Gary and I just did what we said we would do, but he came to play.
    Nathan both lead and followed. Built and shared.
    Struggled and overcame. Lived and learned.
    His excellent efforts were a solid contribution to our build and our community.
    He really rounded out the team. Thanks man. Nice building with you.

    So, it has been quite an adventure. Plenty of variety and lessons.
    I am pushing to wrap up my chair before Christmas.(yet another lame pun)
    Soon I will get going on my matching ottoman.

    As the Great Morris Chair project rolls on...
    it won't be long, before Dewey is driving the bus!
    He has proven to be a great guy, woodworker and soldier.
    Perhaps someone would like to take a ride with him?
    be well,
    Walt
    Last edited by Walt Caza; 11-05-2008 at 12:15 PM.
    There are no shortcuts to anywhere worth going! WCC

    Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind - Dr. Seuss

    Crohn's takes guts. WCC

  9. #204
    Join Date
    Feb 2008
    Location
    Stanwood, WA
    Posts
    3,059

    Thanks Walt!

    My contribution to this thread will officially kick off this weekend. We have a long weekend ahead of us for Veterans’ Day and I plan to spend a good deal in the shop.

    As Walt eluded to, I will be driving the thread soon and it would be great if I could find out where everyone is on their progress/ plans to start… or maybe like, me you were delayed due to some other project which is completely understandable.

    I totally trashed my shop and spent the better part of last week getting it pulled back together and tuned up. I cut a ton of pressure treated pine on my band saw and table saw and fouled up my dust collection system but I have all these things fixed now. I built a new drill press table to (hopefully expedite) the mortise work which lies ahead. I plan on using a mortising attachment and I find the holding device it came with cumbersome at best.

    The beautiful QSWO I purchased is so long I can’t stand it on end in my shop and so it lives on my bench until I get some dimensioning done. I will look to do that first as I really need the use of my bench.

    Hopefully I am correct in assuming that most of the mistakes have already been made by Walt, Nathan, and Gary so all I will have to do is follow along and try not to make the same.

    As part of my trademark (and probably against what Gus would have done), I am going to incorporate some form of inlay or marquetry. I have not yet decided on what to do but it has to be tasteful and not take away from the Arts and Crafts form. I wouldn’t mind hearing your thoughts/ ideas.
    Last edited by Dewey Torres; 11-06-2008 at 12:22 PM.
    Dewey

    "Everything is better with Inlay or Marquetry!"


  10. #205
    Join Date
    Oct 2006
    Location
    Windsor, ON
    Posts
    657
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    Red face my underarms needed help...

    Good Day to SMC,
    The stressful struggle to secure stretchers was a misadventure for sure.(bad for your underarms)

    In hindsight, I recall my concern, when fitting those true through tenons...
    the chair has tons of structure against racking from front to back.
    I hand-fitted the f & b stretchers more snug than usual, which is a huge finesse job,
    in an effort to ensure no side-to-side wobble in the chair.
    Which, I fear, would have sent me looking for a match.(bonfire!)

    It takes many patient test fittings. Try to insert the tenon. No go.
    Take a hair off the tenon. Try again. And again. uggh
    I just wanted to give it every chance against side racking... for now, and later. (seasons fly by)
    You also gotta try not to lever out your mortises too much upon disassembly, lest you injure them.
    See? Tons of side structure, but sparse front and back structure.
    no-racking.jpg

    I was prepared to template rout a set of matching corbels.
    A big part of jig rigging, is knowing when not to jig.
    I realized it may be a looong time before I need 8.75" corbels again.
    So, quicker than I could have rigged the jig, just bandsaw and edge sand. Done.
    I did make a keeper pattern though... for a rainy day.
    corbels.jpg

    I will say it for the last time (thankfully):
    If you are working with parallel clamps, and curved parts...
    keep your offcuts whole, and keep your offcuts handy.
    Here, the top rail offcut is utilized a fourth time, and the corbel offcut also as a caul.
    Yes, I like to use lots of clamps. Not for crushing pressure.
    But for medium, all-over pressure, with oodles of control.
    (when I saw some of my posts here, it looked like a Bessey commercial!)
    rear-corbel.jpg front-corbel.jpg
    Would have been a colourful glue-up without clamping cauls!

    A tip of the hat to Gary... I ripped 1/8 x 1/8" stopcuts at the tablesaw,
    to catch glue, and got zero squeeze-out on the surface mounting.
    Sweet tip! I caught that Nathan liked it too...

    My Darling blue tape was true again. On the saw table for the stopcuts.
    And held the cauls so I could get a clamp on them with both hands. yeehaw

    Just a little sanding, and I will have my decorative, under-arm brackets.(good for your underarms)
    arm-corbels.jpg
    I made them protrude a little more than the plans pattern. I can only be me.
    Hope ya get some shop time,
    W

    ps The chair sits solid, without wobble, at least so far. We'll see what Spring brings?
    Looks like I won't be needing a stick and some marshmallows. whew
    Last edited by Walt Caza; 11-06-2008 at 11:44 AM.
    There are no shortcuts to anywhere worth going! WCC

    Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind - Dr. Seuss

    Crohn's takes guts. WCC

  11. #206
    Join Date
    Feb 2008
    Location
    Colorado Springs, CO
    Posts
    317
    It looks great Walt. You're starting to convince me that I need to tackle my first chair with a Morris Chair.... I got loads of projects to get done first though. Maybe by spinr I'll be good to go!
    Quis custodiet ipsos custodes?

  12. #207
    Join Date
    Aug 2008
    Location
    Kingston, Ontario
    Posts
    1
    David

    Where did you find the drawing for this chair?

    I have been looking for a Morris Chair with this type of sides. Great looking chair

  13. #208

    Thanks Percy

    Here is the link to the plans I used. http://www.craftsmanplans.com/Furniture%20Plans_4.htm
    It is Morris Chair #336. The only problem I noticed was the plans for the holes in the back of the arms show two different spacings. Fig 1 shows holes spaced 1 1/2 In. OC. Fig 5 shows spacing of 1 3/8 in. OC. I didn't notice until I was working on the 2nd chair. The 1 3/8 worked a little better for me. The drawings are clear, but study them carefully. There are no directions per se. My biggest problem was cutting the angled tenons for the rails. For chair 2, I used loose tenons and it worked pretty well. I used caps for the tops of the through tenons on the arms. Have Fun.

  14. #209
    Join Date
    Oct 2006
    Location
    Windsor, ON
    Posts
    657
    Blog Entries
    3

    rear support (pics)

    Hello Everyone,
    The Morris chair seat is held up by a pair of double bevelled seat cleats.
    To rip these bevels on my lefty tilt saw, I prefer to keep the fence on the
    righthand side, away from the blade tilt.
    Once again, I used my tablesaw overlay, as seen here. (link to ZC overlay)
    http://www.sawmillcreek.org/showthread.php?t=89329

    The overlay serves to fill the gap under the ripfence.
    Works great for cutting laminate too.
    I used it earlier to resaw my 3/32" leg veneers on the tablesaw.
    The blank was jointed for a good edge, to start each veneer.
    And were dressed down to 1/16" on the leg after glue-up.

    The overlay was plunge cut with the riving knife removed.(thanks Swenson's for paying full price for that lesson)
    It is held in place by the bump screw and magnetic fingerboard.
    tablesaw overlay.jpg

    My modification to the seat slant has it tilting 6 degrees, as seen in profile.
    seatcleat-bevels.jpg

    The screwholes were done with tapered countersink, and will be filled with tapered plugs.
    A suggestion I learned from John Thompson, to give a more finished look. Thanks Sarge
    seat-cleats.jpg cleat-install.jpg
    The cleats will share and bear the weight of the passengers, and so were
    both screwed and glued for strength and durability.
    take it easy,
    Walt
    There are no shortcuts to anywhere worth going! WCC

    Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind - Dr. Seuss

    Crohn's takes guts. WCC

  15. #210
    Join Date
    Feb 2008
    Location
    Stanwood, WA
    Posts
    3,059

    As promised... the chair work started today.

    I made quite a bit of sawdust today as I began work on the chair. It was nice to move all the wood off my bench and grab a box of chalk to start laying out the cut lines.

    I bought a small bit of flat sawn white oak (FSWO) which I plan to use for the seat slats since you will never see that part anyway. I came out a bit cheaper on lumber that way. That FSWO piece was the first I laid out as I knew which parts I was going to use it for.

    Next a began work on the legs. I am laminating 3 pieces of 3/4" QSWO toegther and using select veneers for the front and back to cover the seams. I got the legs demensioned and cut and the veneers cut as well.

    Total:
    (12) 3/4 x 24" x 2 1/4
    (8) 1/16" veneers x 2 1/2 that will leave 1/8" overlap to trim flush.

    My bandsaw, planer, jointer, and tbale saw got a workout today and WOW, I love the way QSWO smells.

    I will be moving on to the glue up of the legs next.
    Then I will clean the shop and prep for the next step. I am attaching a couple of pics of the veneers and legs before i do the glue up: more to follow!
    Attached Images Attached Images
    Dewey

    "Everything is better with Inlay or Marquetry!"


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