woodbutcher Posted August 16, 2017 Report Share Posted August 16, 2017 29 minutes ago, SeventyFix said: I appreciate all of the encouragement. After some time off, a lot of soul searching and gin, I've decided to make another leg and keep going. I'm heading back out to the garage to make another leg. At least I only ruined one. By the end of today, I'd like to have another leg made with the adder block glued on. Hang in there man. Show this project whos boss. Quote Link to comment Share on other sites More sharing options...
Popular Post SeventyFix Posted August 17, 2017 Author Popular Post Report Share Posted August 17, 2017 3 Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 17, 2017 Author Report Share Posted August 17, 2017 I cut a new leg to replace the one that I cut way too deeply. My suggestion is to take a scrap cut off (there's a lot of them laying around at this point in the project) and cut the dado on it. Doing that allowed me to familiarize myself with the process and dial in the best fit possible. I made 3 cuts in a test piece before getting it just right. The micro adjustment on the depth gauge on the Festool router really helped in this regard. It's possible that other routers have the same feature. Quote Link to comment Share on other sites More sharing options...
gee-dub Posted August 17, 2017 Report Share Posted August 17, 2017 I am a big fan of the "just make another one" approach. If I could get back all the time I wasted trying to "fix" something only to be dissatisfied with the repair . . . There are things you can save and things you can't. Despite the impact to supplies, time or your pocketbook . . . in the end you will be happier you did it right. 1 Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 17, 2017 Author Report Share Posted August 17, 2017 Today's job is to put the round over on the rear legs and fit them onto the seat. Thankfully I have an existing chair leg that I can use as a test piece. Marc does more trimming of the rear legs with the bandsaw, he cuts an angle on the top of the legs to accomodate the headrest and he cancels out the 6 degree slant in the rear legs with an opposite cut to the bottoms. I think that he drills the holes for the screws for all of the legs. I'll be happy if I can get all of that done today, which shouldn't be a stretch. After that, I believe the arms are next. I'm on break from work this week - first time off in a long time. Quote Link to comment Share on other sites More sharing options...
Popular Post SeventyFix Posted August 17, 2017 Author Popular Post Report Share Posted August 17, 2017 2 minutes ago, gee-dub said: I am a big fan of the "just make another one" approach. If I could get back all the time I wasted trying to "fix" something only to be dissatisfied with the repair . . . There are things you can save and things you can't. Despite the impact to supplies, time or your pocketbook . . . in the end you will be happier you did it right. I have to agree with you. I may never make another chair like this again (or I could make another 100, who knows). I don't like the phrase "you're the only one who's ever going to notice". 3 Quote Link to comment Share on other sites More sharing options...
Popular Post SeventyFix Posted August 17, 2017 Author Popular Post Report Share Posted August 17, 2017 I attended a local woodworking club the other night and saw the projects that people were presenting. I'm sure that I am going to offend some people with this comment so please take it with a grain of salt. People were presenting their bird houses, bandsaw boxes, etc. It reminded me why I do this kind of work: not because it is easy but because it is hard. 4 Quote Link to comment Share on other sites More sharing options...
wdwerker Posted August 17, 2017 Report Share Posted August 17, 2017 And hopefully Elon Musk will figure out how to get us back to the moon in the next few years at a much more affordable cost . 1 Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 17, 2017 Author Report Share Posted August 17, 2017 And can we please wean Elon off government subsidies? His "companies" are costing taxpayers a fortune! Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 17, 2017 Author Report Share Posted August 17, 2017 Here's a screen capture from Marc's video series. Notice the arrows as this demonstrates an area where I am now experiencing difficulty. Don't make the same mistake that I did. Notice the top arrow: Marc has left the adder block fairly thick. I ended up cutting mine somewhat thinner. Leave the adder block as thick as possible. You'll notice in the video series that Marc cuts off the minimum amount from the adder block with the 6 degree jig on the table saw. Notice the lower arrow. It's not immediately obvious from the picture but the leg curves back towards the fence. If you cut your adder block too thin (as I did) then the leg will contact the fence. I can't get it to rest against the fence at a 90 degree angle as the leg interferes with the fence. I'm going to try adding a shorter sacrificial fence to my existing fence to allow for the clearance of the leg. Quote Link to comment Share on other sites More sharing options...
pkinneb Posted August 17, 2017 Report Share Posted August 17, 2017 14 minutes ago, SeventyFix said: Here's a screen capture from Marc's video series. Notice the arrows as this demonstrates an area where I am now experiencing difficulty. Don't make the same mistake that I did. Notice the top arrow: Marc has left the adder block fairly thick. I ended up cutting mine somewhat thinner. Leave the adder block as thick as possible. You'll notice in the video series that Marc cuts off the minimum amount from the adder block with the 6 degree jig on the table saw. Notice the lower arrow. It's not immediately obvious from the picture but the leg curves back towards the fence. If you cut your adder block too thin (as I did) then the leg will contact the fence. I can't get it to rest against the fence at a 90 degree angle as the leg interferes with the fence. I'm going to try adding a shorter sacrificial fence to my existing fence to allow for the clearance of the leg. Not sure if you solved this but you could make a quick fence out of plywood short enough on that side to be inside the leg. Just cut a notch for the bit and clamp the plywood fence to the table. Quote Link to comment Share on other sites More sharing options...
Alan G Posted August 17, 2017 Report Share Posted August 17, 2017 2 hours ago, SeventyFix said: I don't like the phrase "you're the only one who's ever going to notice" That's the thing that would make me the most crazy. I would notice....all the time. Glad you are still moving forward on the chair. Looking great! Quote Link to comment Share on other sites More sharing options...
Chet Posted August 17, 2017 Report Share Posted August 17, 2017 2 hours ago, SeventyFix said: not because it is easy but because it is hard. One of my favorite JFK speeches. Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 17, 2017 Author Report Share Posted August 17, 2017 As pkinneb suggested, the solution is straight forward. I took a scrap piece of plywood, cut it in half and attached them to either side of my router fence using double-sided tape. The plywood was cut to about 1.75" in width, allowing for plenty of clearance room for the leg. Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 17, 2017 Author Report Share Posted August 17, 2017 And how did the fit turn out after using a scrap piece to dial in the depth of the dado? As Marc would say "I'd be happy with that". 2 Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 17, 2017 Author Report Share Posted August 17, 2017 And the fit of the legs to the seat? The gaps disappear with "light" clamping pressure. 2 Quote Link to comment Share on other sites More sharing options...
Popular Post SeventyFix Posted August 17, 2017 Author Popular Post Report Share Posted August 17, 2017 Lightly tapped together, sitting on the bench. Might actually become a chair one day. 7 Quote Link to comment Share on other sites More sharing options...
SimonR Posted August 17, 2017 Report Share Posted August 17, 2017 Starting to look like a chair! On a side note i had the sistinct pleasure to sit in one of these this week and absolutely couldn't believe how comfortable it was! Sent from my SM-G920W8 using Tapatalk 1 Quote Link to comment Share on other sites More sharing options...
Chet Posted August 17, 2017 Report Share Posted August 17, 2017 Glad to see it work out. Nothing like some success to make you want to continue after the frustration. Quote Link to comment Share on other sites More sharing options...
..Kev Posted August 17, 2017 Report Share Posted August 17, 2017 Nice work! Way to stick with it! Quote Link to comment Share on other sites More sharing options...
Cheeset202 Posted August 18, 2017 Report Share Posted August 18, 2017 Seventyfix, your next piece will probably be fitting the headrest, I found it helped to clamp a piece of scrap between the rear legs to keep them from splaying apart slightly as you fit the headrest. Marc makes it look a lot easier than it is to fit this piece, go slow taking very small cuts sneaking up on the fit. Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 18, 2017 Author Report Share Posted August 18, 2017 2 hours ago, Cheeset202 said: Seventyfix, your next piece will probably be fitting the headrest, I found it helped to clamp a piece of scrap between the rear legs to keep them from splaying apart slightly as you fit the headrest. Marc makes it look a lot easier than it is to fit this piece, go slow taking very small cuts sneaking up on the fit. I appreciate the advice - I need all I can get. I will keep this in mind. Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 18, 2017 Author Report Share Posted August 18, 2017 An issue that I encountered was that the surface of the rear leg that joins to the arm wasn't perfectly flat. In the future, I would spend extra time making sure that the template is perfectly flat in the areas that will become a joinery surface. This should be obvious to me but wasn't until I started mating the arms to the rear legs. Just something to keep in mind. 1 Quote Link to comment Share on other sites More sharing options...
SeventyFix Posted August 18, 2017 Author Report Share Posted August 18, 2017 A few minutes with a sharp plane took care of the issue. I planed the surface until I got a consistent shaving across the joint. I used a square to gauge my progress. Soon enough the surfaces where flat and square to the side. Quote Link to comment Share on other sites More sharing options...
Popular Post SeventyFix Posted August 18, 2017 Author Popular Post Report Share Posted August 18, 2017 It took a little bit of adjusting to get the arms fitting just right. The joints are tight. Next step is to cut the shape and profile of each arm and drill the half inch hole for the dowel. 4 Quote Link to comment Share on other sites More sharing options...
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