In this video I make a captain's chair for a relative who is around a year and a half old.
I had a rough idea of what I wanted the final chair to look like fairly early on and used SketchUp to refine the design and produce a set of plans. There were still elements of the design that I needed to refine further along the way however.
The project had quite a few complexities and it was a good opportunity to use a plethora of tools and techniques.
The raw materials were few and fairly simple items that are readily available; 18mm softwood plywood (of course hardwood plywood would have been better but I had some spare lying around that I wanted to use), and 16mm and 32mm dowel.
I used many tools for the project, generally using what was most appopriate for the task, but every tool wasn't required and many of them could easily have been substituted had the most appropriate was not been at my disposal. I used a jigsaw, a cross cut saw, a table saw, a panel saw, a japanese pull saw, a hack saw, a belt sander, a disc sander, a drum sander (in a drill press), sand paper, a lathe, a router with router table, a chamfer bit with a follower, a table top drill press, a cordless drill, 16mm, 32mm, and pocket hole drill bits, a bench vice, quick release clamps, spring clamps, chisels, a laser cutter, a tape measure, a ruler, a pencil, and a paint brush. Consumables that I used include PVA glue, pocket hole screws, wood filler, felt pads, and satin polyeurethane based varnish.
I cut all of the pieces out with a jigsaw, made legs out of 32mm thick dowel and side supports out of 16mm thick dowel. I turned the legs on the lathe to add a taper. Starting with dowels was supposed to make the process easier but it was counter productive as the dowels were impossible to centre correctly. If I was to do this again I would start out with larger stock and turn the entire leg rather than just the taper.
I made some simple jigs out of scraps to make angled holes in the seat and armrest of the chair. I made the larger jig for the legs too large the first time because I didn't measure the drill bit and took a guess at it. This meant I had to make some of the jigs a second time.
After drilling all of the required holes, I began assembling the chair. I glued up the seat of the chair, and then glued in the side supports, followed by the armrest, and then the legs. I used a router, a disc sander, a drum sander in a drill press, and sandpaper to complete the shape of the seat and armrest along the way. I also added my branding to the underside of the seat.
During the assembly I found that the holes drilled in the seat to accept the legs were a little innacurate and it meant that the legs had too much play. To get a stronger glue joint and effectively apply clamping pressure I used pocket holes and screws on the legs. I then cut the legs down to their final height and sanded to make it level.
I applied three coats of a satin polyeurethane based varnish, sanding between coats and buffing slightly at the end to acheive a nice sheen. I then added felt pads to the bottom to finish the piece.
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Website: JP Makes
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Music by Ukiyo
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13 сен 2024
