The first step in constructing the chairs that make up the sides of the table is to make the side supports that serve as the rear feet and extend to the front to support the seat slats. These parts have a complicated shape that includes several irregular angles and a curved section on top that forms the seat contour. You could measure to lay out each side support individually, but this takes some time and you run the risk of ending up with parts that aren’t perfectly uniform. A quicker and more accurate approach uses a template-routing technique.
To begin, prepare a full-sized template by transferring the layout information from the templates on page one to 1/4" Baltic birch plywood or hardboard. Cut out the template at the bandsaw and sand the edges until they’re perfectly smooth. Now, trace the pattern onto 5"-wide x 37"-long blanks and head back to the bandsaw to cut out the shapes, remaining approximately 1/16" from all layout lines. Reposition the template on one of the blanks using a few spiral finishing nails or double-sided tape to hold it in place.
Install a bearing-guided flush-trim bit in a table-mounted router and adjust the height so the bearing runs directly against the edge of the template. Using the template as your guide, follow the edge of the template with the bearing, trimming the waste from the blank as you go. A slow, steady feed rate minimizes splintering, especially when you’re running against the grain.
Join the side supports with the front and rear cross braces. The top edge of the front cross braces are bevelled at 62 1/2º to match the profile of the adjacent seat slat that will be added later. The rear cross braces are constructed from a double thickness of 3/4"-thick material for added strength. The top layer of the lamination overhangs the bottom ply at each end by 3/4" to form tabs that rest on top of the side supports. Install the front and rear braces with glue and a pair of stainless-steel screws on each end
Your next assignment is to prepare legs to support the front corners of the chairs. You only need one for each chair because the table carries the load in the centre. Cut out a pair of leg blanks, then prepare a cardboard template for the curved profile that is applied to the bottom (see the plans for details). Trace the pattern onto the boards, cut out the curves and sand the edges. For maximum strength, I used a couple of 2"-long x 1/4"-diameter galvanized carriage bolts to secure the legs to the chair frames.
Line up the parts so the front of the legs are flush with the outside of the front cross brace. The bottom edges of the side supports need to be 8 1/4" from the ground where they meet the back of the front legs. When everything is positioned correctly, use a couple of clamps to hold the parts in place while you drill 1/4"-diameter holes for carriage bolts. Install the bolts with the nuts and washers situated on the inside of the seat frames, where they will be hidden from view. Also, make sure the holes are located so they won’t obstruct the armrest brackets that will be added later. Now, bolt the sides of the chair assemblies to the front and rear table legs following the same procedure. Now you can continue by adding the backrests, seat slats and armrests.
0 Comment