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Published at Monday, November 26th 2018. by in Armchair.

This is my entry for the Rockler modern maker, podcast plywood challenge. I want to design a mid-century modern chair, so I set out finding some designs that I could translate into a plywood version. I use my 3d model to be able to make 2d templates and then imported these 2d designs into an easel. So I could cut the pieces out on my x scarf. So even though these were cut out on a CNC, they did have some rough edges. So after cleaning them up, I started breaking down my plywood and cutting all my pieces to rough dimension apply. What I used for this project was Baltic birch, which comes in a five by five sheet, and I actually ended up only using half a sheet.

No big deal, there was a lot of repetition in this project, so right off the bat, I started roughing out some of my larger pieces before gluing everything up and actually glued this up as a batch just to kind of save on clamps and make sure I wasn't using you know too many clamps. Now, of course, you've cut all of these pieces out, including the templates just on a handsaw Sean Boyd. So I'll put that link in a cart or below so I think for most of my projects, the main power tool that I use is my table saw, but in this case, it was my router table.

see also

Narrow Armchair
Narrow Armchair

So the bits I used were 1/8 inch round over bit a 3/8 round over bit a 3/4 round over bit a half inch flush trim bit and this monstrosity, which I believe is a 3/4 flush trim bit. That's a scary-looking bit be safe. Well, this chair is held together by hopes and prayers and about five different kinds of joinery, starting with my Festool Domino, I use that to do stacked Tenons on the double 3/4 inch laminated pieces that make up the legs and the large side stretcher. How could I not bring pocket holes to the party Here I am putting in the holes which will attach the seat portion to the sides bit of a disclaimer?

I think I dry fit the chair about 10 times throughout the process. I just really want to make sure when I was shaping that I got all my geometry right and I was making sure that all of the pieces lined up where they had to. I did do as much of the shaping as I could on the router. However, I did after the break out the rasp, which was a great skill builder and I did enjoy doing it. But for the sake of time, I put my angle grinder with an 80 grit flap just to work which worked great for a bulk of the material leaving. It loosely fit together, made it a lot easier to pull it apart and do some of the fine shaping, as well as inserting the slots in the C portion, which I later come back and use a weave for to build the base at the chair.

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