Published at Saturday, November 17th 2018. by Jeannine Larsen in Armchair.
I start by making the two rectangles that form the arms of the chair before I can make any cuts at the table saw I first needed to cut the plywood down, even more, to get the pieces to a size that I could manage within my small workshop. So I used my circular saw to make some rough cuts, which were slightly oversized and then I could use my panel sled at the table saw to cut the pieces accurately to the lengths I needed. Then I set my table, saw fence and ripped the pieces to a width based on the measurements.
From my drawing so now I had eight pieces in total two longer and two shorter pieces for each of the two rectangles. I decided to just use wood glue and screws for what would be the bottom of each arm assembly as these screws wouldn't be visible. On the bottom of the chair, after marking up positions for the screws, I added the glue and used a speed square to keep the corners at 90 degrees. I could then drill pilot holes with the countersinking bit and add some 50-millimeter screws.
I used a knife blade to scrape away the excess glue. Next, I added the top panel for the arms just with glued butt joints. Initially, I made sure to get the edges. Nice and flush clamp them in place and put them out in the Sun so that the glue would dry quicker. I then wanted to reinforce those butt joints with some dowels and I'd use some 40 millimeters long 10-millimeter wide beach dowels. For this to get all of the dowels spaced nice and consistently, I decided to make a simple jig out of a scrap of plywood cut to the same width as the arms of the chair. I mucked up the spacing.
I wanted and then marks a line through those marks with a speed square and drilled the holes with a 10 millimeter bit. I used the drill press here to ensure that the holes were at a perfect, 90-degree angle. Then I mucked up 9-millimeters, either side of the line to indicate what would be the 18-millimeter thickness of the plywood and they used some hot glue to stick on another piece of wood to use as a fence lined up with one of those lines. I trimmed off the excess at the handsaw and that was the jig ready to use them, with the 10-millimeter drill bit in my drill, I added some tape to indicate the depth that I wanted to drill the holes too to accommodate the dowels. I could then clamp the jig in place to start drilling the holes.
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