Ebook The art of woodworking classic American furniture: Phần 2

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\AINDSORCHAIR
T
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n. Windsorchairis a
incontrasts.
study
Origi-

the seat at whateverangles
suit its user.All of the chair's
parts are joined with round
mortise-and-tenons-afairly
simplejoint to produce.Some
woodworkerscontend that
one of the benefitsof making
a Windsor chair with green

lumber is that you can take
of the hygroscopic,
advantage
moisture-absorbing
characor
By
ter of wood. dryrngthe leg
tenonsprior to assembly
and
"wet"
morfitting them into
tisesin theseat,a snugjoint will
becomeeventighter.Oncethe
joint is assembled,
the tenon
will absorbmoisturefrom the
woodsurroundingthemortise,
swellingthetenonandshrink-

nallydesigned
asan artless
furnishing,it is now consideredto be a sophisticated
of modernchairmakexample
ing.Thesimpleelements
of a
Windsor-the sculptedseat
legs,
and the hand-shaped
stretchers,
arm posts,and

spindles-beliethe precise
engineering
required
to assembleit. Anddespiteitsrelatively lightweight
components,
the
Windsorchairis verystrong
Thetop of a Windsorchairseatis traditionally
anddurable.
Firstmadein ruralsouthsculptedby hand. With shapingtoolslike
Windsorchairs
thespokeshave,
inshave,and drawknife,it is
ernEngland,
possibleto customize
theseatfor its user.
cameto NorthAmericain the
Perhaps
mid-18thCentury.
as
choose
instead
to useseaOtherchairmakers
design
andunsophisticated
construction, ingthemortise.
aresultof itspractical
pioneerhome- sonedwoodfor theseat,whichwill belesslikelyto crackasit
with America's
thestylequicklyflourished

Thejointsin the
the dries,andreinforce
thejoineryin otherways.
Thefoundation
of allWndsorchairs-whether
steaders.
with chairfeatured
in thischapteraregluedandmanyof themversion
featured
in thischapter,
thecomb-back
sack-back
joints-are furtherstrengthened
by
type-is thesolid- suchastheleg-to-seat
its highbackest,or thecontinuous-arm
"green"(or
inserted
in kerfscutin theendof thetenons.
freshlyfelled) wedges
woodseat.Traditionally
cutfroma
A finaladvantage
of buildinga Windsorchairis thatthe
log,theWindsor's
seatrepresented
animportantinnovation
canbedonewith handtools.Althoughthelegs
in chairmaking.In earlierstyles,
thebackof thechairwasan entireprocess

canbeturnedonalathe(page89),theycanalso
of thelegs.Thismeantthattherearlegshadto be andstretchers
extension
(page
a drawknife
withthespindles-using
seating
andwereattached
to the beshaped-along
bentto providecomfortable
(page
joinery.
horse
7B).Theseatcanbe
76)andashop-built
shaving
complex
seatframewith relatively
(page84),thenshaved
andadzed
to itsfinThelegsof a Windsorchairarenotbent.Instead,
theback cutwithabowsaw
ishedshape.
anchored
separately
to
andlegassemblies
areindependent,

Thesack-back

Windsorchairshownat left wasfinishedwith milk paint, a
traditionalfinishfor AmericanCountryfurniture.,fuailablein powdered
milk paint reflects
form and mixedwith waterto a paint-likeconsistency,
thesimplicityof the Windsorchair;it is bestappliedby brush.

7T


ANATOMYOF A SACK-BACKWINDSORCHAIR
anyof the round mortise-andtenonjointsthathold a Windsor
chairtogetherarereinforcedby wedges.
As the illustrationat right shows,the
top endofthe legs,armposts,andspindlesareallkerfedprior to assembly;the
wedgesthat fill the kerfsexpandthe
tenons,ensuringthat theyfit snuglyin
theirmortises.
Buta Windsorchairis morethanthe
sumof its parts.Forstrengthandcomfort, it alsorelieson the interactionof
The legsand
its variousassemblies.
for example,work against
stretchers,
eachotherto supportthe weightof its
with its bow,
user.The backassembly,
functionsin a similar
arm,andspindles,
manner.Thelegssplayout to the sides
and arerakedforwardandbackwardprovidinga broad,stablebasefor the

chair.As with all enduringdesignsthe
seatis tilted back slightly,making
the chairmorecomfortable.
The threeviewsof the sack-back
on page73 provide
Wndsor presented
spacings,
you with the criticalangles,
and dimensions.More dimensions
appearin the cuttinglist belowand
throughoutthechapterwhereeachpart
of thechairis made.
As you prepareyour stock,keepin
mind that you will not be ableto cut
someof thepartsto theirfinishedlength
Thespinuntil youbeginfinalassembly.
dles,for example,shouldall be left at
their maximum possiblelength-22
inches-until youhavebentthearmand
against
thespindles
bow,andtest-fitted
them.In thesameway,sizethestretchers only after test-fittingthe blanks
betweenthe legs.

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LIST
CUTTING

t

PIECE

OTY.

THICKNESS

Arm
Armposts

I

%'

Bow

2
I

Legs

4

Seat
Longspindles
spindles
Small

1
7

Middle
stretcher
Sidestretchers

2',

W.ORDIAM
2',

44',

IYo'

11',

%u

ARr

!3/o'

17'
20'

16'
3/ou

22',

4

3At

1

T%'

II%'
17'

Ivi'

I4Yz'

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WINDSOR CHAIR

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Side view

Front view

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Top view

thort apindlee
apacedequally
betweenlon1
opindleand
arm poet

1ocketa in
arm for lonq
apindlee
apaced 2'/o
incheoapart


MAKING THE SPINDLES
indsorchairmakingstartswith a
freshlycut log. Becausegreen

woodis swollenandlubricated
with
moisture,
it iseasy
to cleave
andbend.It
isalsolessworkto shape.
Splittingwood
fromalogoffersotheradvantages.
First,

it is stronger,
because

thebreakfollows
thewoodfibersratherthanshearing
them,asa sawmilldoes.And second,
woodseasons
betterif it isshaoed
while
stillgreen.
A chairspindle,
foiexample,
will season
morequicklyandbe less

proneto cracking
thana board,which
maycupor check.
Ifyou haveaccess
to a woodlot,you
canfellyourowntreesusinga chainsaw.
youmaybeableto obtain
Otherwise,
greenlogsfroma sawmill,a localfirewood supplier,or your local roads
Youcanmakean entire
department.
chairfromhardwoods
likehickorywhite
ash,or oak;butmanywoodworkers
also
usesoftwoods
suchaspoplarandpine
for theseat,whichareeasierto shape

with handtools.
Theprocess
described
onthefollowing pagesfor riving,or splitting,a log
into spindleblanlscanalsobeusedto
producearm,leg,andstretcher
blanks.

Oncea loghasbeencut into manageablelengths,it is time to split it.
Driving an iron wedgeinto theendof
thelogwith a sledgehammer,
asshown
at left,will separate
thewoodftbers
alongthegrain. Weareyeprotection
whenyou strikemetalagainstmetal.

PREPARING
THESPINDLE
BLANKS
a boltintoquarters
1 Splifting
I Onceyouhavefelleda logand
trimmedoff the branches,
sawit into
workable
lengths,
calledbolts.Forbest
results,
usea chainsaw.Splittheboltsin

hall (photo,abovd,usinga sledgehammerandironwedges;
wearsafetygoggles
throughout
theoperation.
Tocleave
the
halves
intoquarters,
standthe pieceup,
markthe centeron the endanddrivea
wedgeintothe mark.Continue
driving
thewedgetighl untilthe boltsplits.

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74

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WINDSORCHAIR

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r)

Rivinga quarterboltintoblanks
h a v es p l i ta b o l ti n t oq u a r t e r sr i,v ee a c hp i e c ei n t o
I
Onceyou
s p i n d l eb l a n k sO. u t l i n e
t h e b l a n k so n t h ee n do f t h e b o l ta n ds p l i t
iI (above,left),thenrivethe blankswith a froeand a f roeclub
m a d ef r o ma n 1 B - i n c hl e n g t ho f d e n s eh a r d w o o sdu, c ha s m a p l e ,

-) Debarkins
theblanks
<.

h i c k o r yd, o g w o oodr e l m . H o l d i n g
t h e f r o ei n o n eh a n dw i t ht h e
bladeoffsetfromtheoutline,strikethe bladewiththe club (above,
ilghil.fwislthe froebackandforth,anddriveit in deeper.0nce
t h e w a s t eb r e a k so f f, r e p e atto m a k et h e r e m a i n i ncgu t s .

r - J R e m o v eb a r kf r o my o u rb l a n k su s i n ga d r a w k n i f o
en a
i n b o t hh a n d sw i t ht h e b e v e dl o w n ,p u l l t h et o o lt o w a r dy o u

h o r s e( p a g e/ B ) . S e c u r e
s h o p - b u i sl th a v i n g
t h e w o r k p i e cbea r k t o s h a v eo f f t h e b a r k( a b o v e )T. u r nt h e p i e c ea r o u n dt o d e b a r k
s i d eu p u n d e rt h e h o r s e 'csr o s s b aTr .h e n ,h o l d i n gt h e d r a w k n i f e t h e o t h e re n d .


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WINDSORCHAIR

SHAPING
THESPINDLES
ANATOMY
OFSPINDLE
-/,."
dta. +i

i

)/

l:
' ) i

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'l

'/ "

dia.

'>i
!Long epindle

Rough-shaping
thespindles

I Secure
a s p i n d l eb l a n ki n y o u rs h a v r nhgo r s ea n d u s ea d r a w k n i fteo s h a p e
t h e s t o c ki n t oa t a p e r e dc y l i n d e rF. o rb e s tr e s u l t st,h e g r o w t hr i n g so n t h e e n d
g r a i no f t h e b l a n ks h o u l db e r o u g h lvye r t i c aS
l . t a r tb y s q u a r i nagn ds i z i n gt h e b l a n k .
Holding
t h e d r a w k n i foen t h e b l a n kb e v esl i d ed o w n ,p u l lt h e t o o lt o w a r dy o u ,
a l w a y sf o l l o w i n tgh e g r a i n( a b o v e )K. e yd i m e n s i o nasn d d i a m e t e rfso r t h e s e v e n
l o n gs p i n d l eas n df o u rs h o r ts p i n d l eyso u n e e df o r a c h a i ra r ep r o v i d eidn t h e
i l l u s t r a t i oant l e f t .T u r nt h e b l a n ke n d - f o r - e nadn d r e p o s i t i oi nt i n t h e s h a v i n g
h o r s ef r e q u e n t lsyo y o uc a ns h a p ei t u n i f o r m l yP. e r i o d i c a cl l hy e c kt h e p i e c e ' s
k e yd i a m e t e rwsi t hc a l i p e ros r a s h o p - m a dgea u g el i k et h e o n es h o w no n p a g e7 7 .
( l f y o up r e f e ry, o uc a nt u r nt h e s p i n d l e o
sn a lathea
, s s h o w no n p a g e8 9 . )

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WINDSORCHAIR

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r) Evening
outthe spindles
L O n c ea l l t h e s p r n d l eas r er o u n d e d
a n dt a p e r e du, s ea s p o k e s h a vt oee v e no u t
t h e i rs u r f a c e sA. d j u s t h e s p o k e s h a vf oer a v e r ys h a l l o w
c u t . H a n d l et h e t o o la s y o u
d r dt h e d r a w k n i f ea,l w a y sw o r k i n gw i t h t h e g r a i n( a b o v ea)n d r e p o s i t r o n i tnhge w o r k p i e c ea s n e c e s s a rF
y .o r mt h e t e n o n sa t t h e b o t t o me n d so f t h e s p i n d l e w
s i t ha k n i f e ,
r e f e r r i ntgo t h e a n a t o m yi l l u s t r a t i oonp p o s r t e .

jiiilIi ffi dr{il ffi tulil tiJill, iiiji$ ,u{lr,itrjdi d,
1HO?Tt?

,r:

ShoV-madesizinggau6e
//
A ehog-made

oizingqauge
-'//
alloweyouto meaeure
trhe
diamelersof chaireVindleeae youohapethem.
Soreholesinlo a wood
ecrap,eizingLhemaccordinq
to NhesVindleo'
keydiameters.
Dnlla
'/,.,-inch-diameLer
holeinto the qaugeLo
-/

-)t

{,r-,2

checkNhetenon aI Lhe boLLomend of Lhe
e p i n d l e ea, n d a 7 / , , - i n c h - d i a m e t h
ea
r l ef o r t h e
f , o Ve n d o f l h e o p i n d l e s . Y o cua n a l s o c h e c ka k e y
d i a m e l e r a l o n gL h e l e n q l h o f t h e e p i n d l e ob y b o r i n q a h o l et h r o u g h L h e q a u q ea n d e l i p p i n gI h e b l a n k
introf,he hole.Ihe blankis lhe correcl diamet,erwhen iL
j a m e i n N h eh o l ea I L h e a p p r o p r i a t ep o i n l a l o n qi t o l e n g f , h .

S m o o t h i nt hges p i n d l e s
Q
r - . 1 U s ea h a n ds c r a p etro g i v et h e s p i n d l e sa s m o o t hf i n i s h G

. r a s p i ntgh et h i c k
e n d o f t h e s p i n d l ei n o n eh a n da n d ,
bracing
t h e t h i n e n do n a w o r ks u r f a c e ,
u s ey o u ro t h e rh a n dt o d r a wt h e s c r a p e r
. o r kr n t h e
a l o n gt h e s u r f a c e( a b o v e )W
d r r e c t i o on f t h e p r a r na n d r o t a t et h e
spindle
f r e q u e n ttl oy k e e pi t u n i f o r m .


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WINDSORCHAIR

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Eridge
2" x 10"x 35"

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Eench
3"x10"x72"

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Foot bar

Adiuetment hole
Pivoting arm
aeaembly

Erace
1'1"x3'/2"x13"
Pivoting
lag bolt

Leg
2"x4"x19/2"

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A SHAVIilG
HORSE
Theshaving
horsegripsstocksecurely
in placewhileit isshaped
withdrawknivesandspokeshaves.
Simpleto
horse
features
build,thetypicalshaving
a bench,
an inclined
bridge,
anda pivBystepping
otingarmassembly.
down
ontheassembly's
footbar,youcanlock
yourworkpiece
in position
between
the
bridgeandtheassembly's
crossbar.
To buildtheversion
shownabove,
with
bench,
which

canbe
start
the
from
half
log
10
12
inches
hewn
a
to
in diameter,
from
rough
orcutto length
3-by-10lumber.
Makethelengthof
the benchto suityourneeds.
Next,cut the legsfrom2-by-4
stockandattachthemto the bench

joints,reinforced
T half-lap
withangled
byscrewsandbracestighil. CutIhe
twobracestrom2-by-4stockto fit
between
the leg'soutside
edgesand

screwthemto the legs.To bevelthe
of the legssotheysit flat and
bottoms
level,settheshaving
horse
on a flat
surfaceandbutta squareboardup
against
all foursidesof eachlegto
markcuttinglinesaroundthem(page
79, above,/eft).Sawthe bottomsof
the legsflat,thencutthetopsof the
legsflushwiththebench.
Next,sawtheriserandthebridge
to
size;therisershouldbecut andbevis inclined
eledsothatthebridge
at an
angleof about15'to thebench.
Locate
the riserabout30 inchesfromthe

backof thebenchandscrewit in place
fromunderneath.
Thenscrewthebridge
to the riser(page79, above,right)and
thefrontof thebridge
io the bench.

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WINDSORCHAIR

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N e x tb, u i l dt h ep i v o t i nagr m .T h e
bly.Cutdadoes
in thefootbarto match
a s s e m b cl yo n s i s tosf t w oa r m s a,
thenotches

in thearms,fit thepieces
notchedcrossbar,anda footbar
together,
andreinforce
thejointswith
(right)Thecrossbar
is joinedto the
screws.
Withthefootbarattached.
slio
armswiththrough
roundmortise
and
thearmassembly
undertheshaving
tenons,
whilea bridlejointconnecis
horseandscrewit in placewiththe
thefootbarto thearms.Cutthearms
from2-by-4stockandboretwocountersunk
holes
through
eachoneforlag
PIVOTINGARMAS?EMELY
screws.
Makeadditional
holes
through
the armsaboveandbelowthe f irst
soyouwill beableto adlustthe positionof the assembly

laterto accommodate
thrcker
stock.To oreoare
the
armsfor the bars,cut a roundmortisethrough
themat thetopendand
a notchat the bottom.
Next,cut thecrossbarto length,
making
it about3 inches
longer
than
width
the
of the bench.Cutround
in bothendsanda V-shaped
tenons
notchin themiddleof thebottom
edge
to holdyourstock.Setthecrossbar
asidefor now.Next,cut thefootbar,
m a k i n igt s l e n g t h
t w i c et h a to f t h e
crossbar
to provide
anoctagonal-shaped
footrestoneachsideof thearmassem-

79

lagscrews.
Donottightenthescrews
immediately;
leave
themloose
enough
soyoucanslipthecrossbar
in place.
Do
notglueor screwit, butleavethebar
freeto pivot.Onceit isconnected
to the
arms,f inishtightening
thelagscrews.

Lag screw


MAKING THE BOW AND ARM
-l- h. arm and bow of the sack-back
I Windsoranchorthechair'sbackrest,tying the spindlesinto a strong
and comfortablestructure.The graceful curvesofboth piecesareachieved
that
throughsteambending,a process
part
maywell be the most challenging
of makingthe chair.
of woodThetwo essential
elements
steamingarea steamgeneratorand an

Theversionshownin
enclosedsteamer.
on page
thephotoat right anddescribed

from ABSpipe.Besure
83is shop-made
longerthanthebow
to makethesteamer
and arm,and sealit tightlyto keepthe
steamfrom escaping.Includea small
drain hole at one end and olacethe
to
steameron a slightincline,however,
allowthe condensed
steamto run out.
Ifyou areusinga gas-powered
steam

source,it is safestto do your steaming
outside,If you areusinggreenwood,
l5 to 20 minutesof steamingshould
makethe piecesufficientlypliableto
bend arounda form. Air-driedlumIt
berrequirestwiceasmuchsteaming.
will takeabout one weekfor a bent
pieceof l-inch-thickstockto dry.

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The arm of a sack-backWindsorchair
is extractedfrom a steamingjig with a
pair of tongs. The steamingprocess
leavesthe wood pliable for about a
minute-long enough to bend thepiece
around a form. Becauseof the intense
heatproduced, always wear work gloves
when handling steamedwood.

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ANATOMY

OFA BOWANDARM

r
22" (from end to middle)

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',,>,,

dia.

,

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t
22'/r" (from end to mtddte)

t
%" dia.

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80

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T

WINDSORCHAIR

PREPARING
THESTOCK
thebowandarm
1I Squarine
I

D r a w k n i fteh e b o wa n da r m r o u g h ltyo

c,izp (naop

74)

lhon

rrc.p: hon.h

nlanp

to scuare
t h eo i e c ea
s n df l a t t e nt h e i rs i d e s .
Secure
t h e b l a n kb e t w e e b
n e n c hd o g so n
y o u rw o r k b e n c hS.t a r t i n g
a t o n ee n d o f
t h e s t o c k g. u i d et h e p l a n ea c r o s tsh e s u r f a c et o t h e o t h e re n d :k e e pt h e s o l eo f t h e
t o o lf l a t o n t h e w o r k p i e caen da p p l ym o d eratedownwardpressure(right).Planethe
a r mu n t i li t i s I b y I i n c h e sf ;o rt h e b o w .
r e f e rt o t h e a n a t o m iyl l u s t r a t i oonp p o s i t e .

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r ) S h a p i ntgh eb o wi n t oa c y l i n d e r
L Secu,ethe
b o wb l a n ki n y o u rs h a v i n g
h o r s ea n ds t a r t
s h a p i ntgh e p i e c ew i t ha d r a w k n i f e
B.r a c i ntgh e e n do f t h e
s t o c ka g a i n syt o u rc h e s t d
, r a w k n i fteh e b l a n ki n t oa c y l i n d e r
( l e f t )w
; o r kw i t ht h e w o o dg r a i nt h r o u g h o uAt .s s h o w ni n t h e

diagram
o p p o s i t em, a k et h e f i n a ld i a m e t eor f t h e b o wI i n c h ;
i t s h o u l dt a p e rd o w nt o I i n c hs t a r t i n ga b o u tB i n c h e sf r o m
e a c he n d .A s y o uw o r ko n t h et h i n n eer n do f t h ew o r k p i e c e ,
r e p o s i t i otnh e b l a n ki n t h e s h a v i n g
h o r s es o t h a t l e s ss t o c k
f
r
o
m
e x t e n do
sut
u n d e rt h e c r o s s b a S
r .w i t c ht o a s p o k e s h a v e
to givethe bowa smoothersurfacetinish (above),
handlingit
a s y o ud i d t h e d r a w k n i f e .


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WINDSORCHAIR

'l

BENDING
JIG

6

B u i l d i nag b e n d i njgi g
I B u i l da b e n d i ntgi g l i k et h eo n es h o w n
at leftto bendthe bowand arm of a sackb a c kW i n d s ocr h a i r .C u t t w o p i e c e so f
%-inchplywoodto the desiredcurveof the
b o wa n d a r m ,t h e ns c r e wt h e m t o g e t h e r
t o m a k et h e f o r m .M o u n t h e f o r mo n a
% - i n c hp l y w o o d
b a s ea n d m a r kt h e c e n t e r
o f t h e f o r mn e a ri t s t o p e d g e T
. h e nc u t
t h e s t o pb l o c kf r o m h a r d w o oadn d s c r e w
i t t o t h e h a s e a n d h o r et h e t w o Z - i n c h d i a m e t edr o w e lh o l e si n t ot h e b a s e T
. he
s p a c eb e t w e e nt h e b l o c ka n dd o w e l sa n d
t h e f o r ms h o u l de q u a tl h e t h i c k n e sosf
t h e w o r k p i e cpel u st h e w e d g e su s e dt o
qc.rrrp it in nlanp

Fin:llv

nron:ro tho

d o w e l sa n d w e d g e st,h e nc l a m pt h e b a s e
to a worksurface.

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Securing
thebowaround
theform
O n c et h e w o r k p i e chea sb e e ns u f fi c i e n t l ys t e a m e dr.e m o v e
i t f r o mt h e s t e a m e(rp a g e8 0 ) a n dp l a c ei t o n t h e b e n d i n g
1ig.

A l i g nt h e m i d d l eo f t h e b o ww i t ht h e c e n t e rm a r ko n t h e f o r m
a n d c l a m pt h e s t o c kt o t h e m i d d l eo f t h e f o r mb y t a p p i n g
w e d g e si n p l a c e .P u l lo n ee n d o f t h e w o r k p i e cteo w a r dt h e
f o r mf i r m l ya n d s t e a d i l yu n t i l i t c o n t a c t st h e s i d eo f t h e f o r m .
Insera
t d o w e li n t ot h e h o l ei n t h e b a s ea n d t a p i n a w e d g e
t o s e c u r et h e b o wi n p l a c e .R e p e afto r t h e o t h e rs i d eo f t h e
. o r kq u i c k l yt o c o m p l e t teh e b e n d .
w o r k p i e c e( a b o v e )W

Maintaining
thebendwithstring
T i ea l e n g t ho f s t r i n gt i g h t l yb e t w e etnh e e n d so f t h e b o w
( a b o v e ) a nbde g i ns t e a m i n tgh e a r m .0 n c et h e a r m i s r e a d y
f o r b e n d i n gy, o uc a n r e m o v e
t h e b o wa n d b e n dt h e a r m a s i n
s t e p2 . T h es t r i n gw i l l k e e pt h e b o wb e n tu n t i l i t d r i e s .

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PIPE
STEAMER
A SHOP-MADE
anddurable
wood
An economical
liketheoneshownbelow
steamer
from2-by-4s
and

canbefashioned
4 - i n c h - d i a m eAt B
e rSp i p ea n df i t features
support
tings,Thedevice
racksinsidethe pipeanda removablecapat eachendforeasyaccess.
is a watercanconThesteamsource
bya lengthof
nected
to thesteamer
plastichose:thewaterin the can
cooker.
is heated
bya propane-fired
(Thissetupshould
onlybeusedoutThesteamsource
should
doors).
cap.
havea removable,
screw-type
startwitha
Tobuildthesteamer,
lenghof schedule
80 ABSpipelonger
thanthebowandarm.Cutit in half
both
of holes
through
anddrilla series

pipehalves
to accommodate
%-inch
machine
boltsandnuts
zinc-coated

(DETAIL)
STEAM 1OUKCEFTTTING
y?u'

7[aeLtc hoae
to Iteamer

couplinq

Theseboltswillsupport
asshown.
it
to prevent
woodinsidethesteamer
water.(The
fromlyingin condensed
theboltsfrom
zinccoating
willprevent
Drillthe holes
staining
thewood).
thecenterline

of thepipeto
below
provide
roomforthewood.Install
the
washers
bolts,usingsteelandrubber
Kemovableend cap

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' '"(-""
tanK

MachirtenuL
(ineide eream

aaa cooker

83

Kubber 1aokeL

seal.
onbothsides
to makeanairtight
of thepipeto an
Nowgluebothhalves
Drilla %-inch
drain
ABST connector.
moisture
holeat oneendto release
pressure.
Thengluea
andexcess
pipecutfrom1%-inch
ABS
connector
pipeto thespouiof theT connector.
Next,cut a lengthof plastichose
to the
thatwillconnect
thesteamer
for
watercan;thef ittingsrequired

thewatercanendareshownabove.
(Thefittingsforthesteamer
endof
except
thatan
thehoseareidentical,
ABSendcapis usedinstead
of the
watercancap;theendcapisglued
pipe.)
andscrewed
to theconnector
Makesurethef ittingsareairtight.
Lastly,builda 2-by-4frameto supportthesteamer.
Naila smallsupport
will
blockat oneendsothesteamer
andtheexcess
restona slightincline
waterwillrunoutof thedrainhole.
conTo usethesteamer,
carefully
nectthe gascooker
to a propane
tank.Fillthe watercan,attachthe
capandhoseto it, andsetthecanon
end
thecooker.
Secure
theremovable

lightthecooker,
capsonthesteamer,
buildup steam.
andletthesteamer
(Caution:
or
Donot let the steamer
pressurized.)
steamsourcebecome


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MAKINGTHE SEAT
rla he seatof a sack-back
Windsor
I chairisbestcut from a singleplank.
As shownin thephoto at left,theblank
is roughedout by hand with a frame
sawor bowsaw.Then the seatis given
its basicshapeusinga varietyof hand
tools-the edgesareroundedoverby a
drawknife(page85),the top surfaceis
scooDedout with an adze and an
inshave(page86),andsomefinaltouchesareetchedwith a veiner(page87).

Thefinal stepis to boremortisesinto
the seatfor the legs,spindles,and arm

posts(page90).Asshownin the anatomv illustrationbelow.the arm oost
mortises
arethelargest:
%inchin diameter;thelegmortisesare%inchin diameter,while the spindlemortisesmust
bit.
be drilledwith a %-inch-diameter
Referto the diagram for the seat's
dimensionsand for the location and
spacingof the mortises.

SEATDIMENSIONS
ANDANGLES
OVERHEAD
VIEW

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A framesawcutsa Windsorchair
seatblankfrom a pineplank.
Theblankwill beshapedlater
with a varietyof hand tools.It
couldalsobecut on a bandsaw.

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'IDEVIEW
16"

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WINDSOR CHAIR

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THESEAT
SHAPING
0utliningthetopsurfaceof theseat
1
I S a wy o u rs e a tb l a n kf r o ma p i e c eo f
2-inchlhick pine(page84), thenoutline
out. Startby markthe areato be scooped
i n gt h e c e n t e ro f t h e b l a n k ' sf r o n te d g e .
N e x t ,m a r ka l i n e2 k i n c h e si n f r o me a c h
s i d eo f t h e b l a n kt;h e l i n e ss h o u l db e p a r allelto the frontedgeand4% inchesaway

f r o mi t . D r a wa c u r v e dl i n et h a tj o i n st h e
t w os i d em a r k sa n dp a r a l l e ltsh e s i d e sa n d
backedgeof the blank (lefil. Finally,draw
t w o c u r v e dl i n e st h a t c o n n e ctth e s i d e
m a r k sa n d t h e c e n t e rm a r ka t t h e f r o n t
e d g eo f t h e b l a n k t; h e s el i n e si n d i c a t e
w h e r et h e t o p s u r f a c eo f t h e s e a ts l o p e s
towardthe frontedgeand are represented
b y t h e d o t t e dl i n e si n t h e i l l u s t r a t r o n .

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r) Rounding
overtheblank
L Clu^otheblankin a viseandusea drawknife
to roundover
thecircumference
of theblankand
itsedges.
Tobegin,
smooth
f ei t ht h eg r a i n
r o u n do v e ri t su n d e r s i dpeu, l l i n tgh ed r a w k n iw
(above,
lf you
/eff);repositton
theblankin theviseasnecessary.

it gradually,
rather
a knotin thewood,cutaround
encounter
with
stroke.
Then
usethe
to
hack
through
it
a
single

thantrying
along
the
front
form
flat
lip
on
the
top
surface
drawknife
to
the
40'
right).
cut
at
about
edgeof theblank,angling
the
bbove,

85


WINDSOR CHAIR

n<' Dishins
outtheseat

r . , l O n c et h e c i r c u m f e r e n coef t h e s e a t
h a sb e e ns h a p e d r, o u g ho u t t h e w a s t e
f r o mt h e t o p s u r f a c eu s i n ga g u t t e ra d z e .
W e a r i n gs t e e l - t o e db o o t s ,s t e po n t h e
e d g e so f t h e b l a n kt o h o l di t s t e a d ya n d
c h o po u t t h e s i t t i n ga r e af r o mo n es i d eo f
the outlineto the other(lefil.f ry to cuI
w i t ht h e g r a i n ,u s i n gs h o r ts t r o k e sM
. ake
s u r ey o u rf e e ta r en o t i n t h e p a t ho f t h e
b l a d eC
. ontinuu
e n t i ly o u h a v ec u t a b o u t
% i n c hd e e pi n t h e c e n t e ro f t h e s e a tw i t h
a g r a d u asl l o p ef r o mt h e c e n t e ru p t o t h e
s i d e sa n df r o n ta n d b a c ke d s e s .

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Smoothing
theseat
Securethe seatbetweentwo bench
d o g so n y o u rw o r k b e n c hp,r o t e c t i ntgh e
s i d e sw i t h w o o dp a d s .S t a r tw i t h a n
i n s h a vteo s m o o t ht h e r o u g hs u r f a c el e f t
b yt h e a d z e W
. o r k i n fgr o mo n es i d eo f t h e
t o ps u r f a c e
t o t h e o t h e r ,h o l dt h e i n s h a v e
w i t h b o t hh a n d sa n d p u l l i t t o w a r dy o u ;
alwaysfollowthe grain(righil.Usea convexspokeshave,
or travisher,
to refinethe
smoothness
of the seat(photo.page7 l).

86

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WINDSOR CHAIR

thelip
f, Shaping
r-,f Thelip at thefrontedgeof theseat
. orking
h a sa s l i g h d
t o w n w a rbde v e lW
on onesideof theseat'sfrontedgeat a
o c u tt h e
l r a w k n i ft e

t i m e ,u s ea s m a l d
the
comfort,
lip (right).Formaximum
o u tD o r t r a n s i t i obne t w e et nh ed i s h e d
be
should
tionof theseatandthebevels
be
Thesameshould
smooth
andgradual.
between
thebevels
trueof thetransition
thecircumferandthef latsection
around
thelip
smoothing
enceof theseat.Finish
witha sookeshave.

Carving
thechannel
U s ea % - i n c vhe i n etro c a r v et h e c h a n -

nelthatseparates
theseat'sscooped-out
fromtheflatsection
around

topsurface
(left).Thisis a decoits circumference
to sharpen
the
rativegroove
designed
t r a n s i t i obne t w e et n
h ec u r v e a
d n df l a t
oortions
of theseat.


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POSTS,AND
MAKINGTHELEGS,ARM
STRETCHERS
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tlt h. legs,stretchers,
guideto producethe turnings.Referto
andarm postsof
I aWndsorchaircanbeshaoed
with
theillustrationbelowfor dimensions.
and
I
a drawknife,but manywoodworkers usecalipersto checkkeydiametersas
work with a latheinstead,usinga story

thework progresses.
Startby turningthe
I
polefor eachcomponenl(page52)asa
legsand the arm posts.But beforeyou
you haveto bore
canturn thestretchers.
I
the leg mortisesin the seatand test-fit
A handbracefixed with a spoonbit
thelegsin place.By measuringtheexact
I
boresa mortisein onesidestretcher
distancebetweenthelegswith the chair
of a sack-backWindsor
chair.The
test-assembled,
the stretcherscan be
I
mortisewill housea tenonof the
sizedwith precision.
Themortisemust
The tenonsthat join the pieces
middlestretcher.
I
you
beangled;a spoonbit enables
together-at thetop endsof thelegs,the
to start drilling theholestraight
bottomsof the arm posts,and at both

I
the
inch
before
tilting
the
endsof the stretcheri-are taperedto
for
first'/
lock the tenonsinto their mortises.
toolto thecorrectangle.
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ANATOMY
OFTHELEGS,
ARMPOSTS,
ANDSTRETCHERS
LEG

MIDDLE
5TRETCHER

ARMPO9T

SIDE
STRETCHER

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Note: All dimeneione are
dia meters, etaept where
apeaified ao length.

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W I N D S O RC H A I R

TURNING
THELEGSANDARMPOSTS
'l Shaping
thelegsandarmposts
I

I l V o u nitn e b l a r k b e t w e e cne n t e r so n
y o u rl a t h ea n d u s ea r o u g h r nggo u g et o
p r o d u cteh et u r n i n gR. e f etro t h e a n a t o '
m y i l l u s t r a t i oonp p o s i t feo r t h e l o c a t i o n s

a n dd i a m e t e rosf d e c o r a t i veel e m e n t lsi k e
h e a n sa n dc n v p qO n c ev o ua r es a t i s f i e d
w i t ht r e t u r n r n g s' sh a p ef.o r mt h et a p e r e d
. r
I e n o na t t h e a p p r o p r i a Leen d ( r i g h r )O
, s s h o w nt,h et e n o ns h o u l db e
t h e l e g sa
2 , / i n c h e sl o n g t, a p e r i n fgr o m 1 i n c ht o
, / ' n c h i n d i a m e t e rM
. a k et h e a r m p o s t
f r o m / , ,I o
t e n o n s1 i n c h l o n g ,t a p e r i n g
/ , l n c hi n d i a m e t e F
r .r n a l l yt u, r na s h a L
I n wp r o o v e
o n e a c hl p st o i n d i c a t e
the
will
l o c a t i o no f t h e s t r e t c h e r tsh; i sg r o o v e
d o ub l ea s a d e c o r a t i veel e m e n t .
| u

U v v l J .

v | | ! v ,

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r ) S m o o t h i nt hget u r n i n g s
Z R . r o u . t h e r o o lr e s ta n d f o l d a
n i e c eo f 8 0 - s r i ts a n d n a o ei nr t h i r d st o
p r e v e nt th e p a p e frr o ms l i p p i n gS. w i t c h
o n t h e l a t h ea n d h o l dt h e p a p e ra g a i n s t
t h e t u r n i n gW
. o r kw i t ht h e g r a i na l o n g
thp lpnorh nf ihp nipco:c

mrrnh 2q nnq-

s i h l e/ i e f l ) b e i n pc a r e f r rni o t t o r o r , n d
o v e rt h e d e c o r a t i veel e m e n t os n t h e
cJ Lt n
u 'i uopn
Un
L 'k\ . s

q:ndino

n upr rr iU^Uf l, L; ^c l^l iy l
p

, , +L U^ ^ - ^

Prs-

v e n tb u r n r n tgh e w o o d W
. o r kw i t h p r o ,
o r o q q i v o l v f,i ,n,p, r, ,n : n p r c
r * Y - , - . i t o p p l n gw n e n
you reach224 griL

89


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WINDSORCHAIR

TUR N I NTG
H EST E T C H E R S
'l
l

Marking
thelegandspindle
-

I mortises
on theseat
B e f o r ey o u c a n t u r n t h e s t r e t c h e r sy,o u
n e e dt o b o r et h e l e g m o r t i s e si n t ot h e
s e a t ,t e s t - f i t h e l e g si n t h e m o r t i s e sa,n d
m e a s u rteh e d i s t a n c ebse t w e e tnh e l e g s .
S t a r tb y m a k i n ga t e m p l a t eo f t h e s e a t
f r o m l - i n c h h a r d b o a r dr e, f e r r i ntgo t h e
a n a t o m yi l l u s t r a t i oonn p a g e8 4 f o r t h e
d i m e n s i o nosf t h e s e a ta s w e l la st h e l o c a t i o n a n d s i z eo f t h e l e ga n ds p i n d l em o r t i s e s .D r i l la h o l et h r o u g ht h e t e m p l a t ea t
e a c hm o r t i s em a r k ,t h e ns e tt h e s e a to n a
w o r ks u r f a c ep, o s i t i o n
t h e t e m p l a t ea t o p
it, and marktheholes(right).

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r) Drilling
thelegmortises
t ^ ,

4 , - C l a m pt h e s e a td o w na n df i t a h a n d
b r a c ew i t ha s p o o nb i t t h e s a m ed i a m e t e r
a st h e s m a l le n do f t h e l e gt e n o n sU
. s ea
straightedg
ae
n da s l i d i n gb e v e l t oh e l p
y o ud r i l lt h ec o m p o u n d - a nhgol el e sT. h i s
w i l l e n a b l et h e l e g st o s p l a yo u t f r o mt h e
s i d eo f t h e s e a ta t t h e p r o p ear n g l ea n d
be angled-or raked-towardthe frontor
b a c ko f t h e c h a i r .P o s i t i otnh e s t r a i g h t pdsp anrnqq fhc cp:f ai tf
_ _ _ ._ . . , t ec o r r e csl p t a y
a n g l eo f 1 0 5 " ,o r 1 5 ' f r o mt h e p e r p e n d i c u l a r( p a g eB ) . f h e n a d j u s t h e s l i d i n g
b e v etlo t h e r e q u i r e rda k ea n g l ew
, h i c hi s
I 0 0 " f o r t h e f r o n tl e p sa n d I I 5 " f o r t h e
r e a rl e s s .o r l 0 o a n d? 5 ' f r o mv e r t i c a l .
P o s i t i otnh e s l i d i n gb e v e l o nt h e s t r a i g h t e d s e T h e n c e n t e trh p h i t o n t h e m o r t i s e
m a r ka n db e g i nd r i l l i n gk,e e p i ntgh e h a n d
l t h e s t r a i g h t e d gaen dt h e
b r a c ep a r a l l et o
b i t l i n e du p w i t ht h e s l o p eo f t h e b e v e l
(lef). Repeatthe procedureto borethe
r e m a i n i nlge gm o r t i s e s .

90

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WINDSOR CHAIR

Tapering

thelegmortises
O n c ea l l t h e l e gm o r t i s ehs a v eb e e n
d r i l l e d r. e m o v teh e s p o o nb i t a n d i n s t a l l
a t a p e r e dr e a m e rT. h i sd e v i c ew i l l g i v e
t h e l e g m o r t i s e sa t a p e r e ds h a p et h a t
m a t c h e st h e c o n i c asl h a p eo f t h e l e g
t e n o n s l,o c k i n gt h e l e g st o t h e s e a t .
S e c u r et h e s e a ti n a v i s e ,t h e nt a p e r
e a c hl e gm o r t i s es, t e a d y i ntgh e h a n d
Periodbraceagainstyourchest(above).
i c a l l yt e s t -ift t h e l e g si n t h e i rm o r t i s e s ,
r e a m i ntgh e h o l e su n t i lt h e f i t i s s n u g .

thesplayandrakeofthelegs
,{ Checking
r+
Testjitthefrontlessin theirmortises
a n dc h e c kw h e t h et hr e i rs p l a ya n dr a k e
Tohelpyougauge
the
angles
areuniform.
across
rakeangle,placea straightedge
t h el e g st;h eb o a r ds h o u l db e p e r f e c t l y
lavol /lpff)

Roncaf

fnr the ro:r

looc

lf

a n yo f t h e a n g l e sa r eo f f s l i g h t l yy, o u
c a nc o m D e n s aftoer m i n o ri n a c c u r a c i e s
w h e nt h e t i m e c o m e st o t u r n a n d i n s t a l l
thp circinhcrs

(naoe
\Fvbv

Q2)

r1r'


WINDSORCHAIR

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f, Sizingthe sidestretchers
.-,1 Set the seat-and-leg
assembly
on a worksurfaceand meaf
r
o
n
ta n d r e a rl e g so n o n es i d e
s u r et h e d i s t a n c eb e t w e e tnh e
(above),
your
grooves
measure
with the stretcher
aligning
tape
y o ut u r n e di n s t e p1 . R e p e aot n t h e o t h e rs i d eo f t h e s e a t .T o
t h e l o n g eor f t h e t w o m e a s u r e m e nat sd,d 1 %i n c h e sf o r t h e
t e n o n sa t e a c he n da n da n a d d r t i o n a
%l i n c ht o h o l dt h e l e g s
i n t e n s i o nw h e nt h e c h a i ri s a s s e m b l e dB.y s i z i n gb o t hs t r e t c h r e a s u r e m e nt ht ,e r a k ea n g l eo f t h e
e r sa c c o r d i ntgo t h e l o n g e m
t w o l e g sw i l le q u a l i z e .

thesidestretchers
fi Turning

a n dm o u not n e
\ , f C u tt h es i d es t r e t c h ebrl a n ktso l e n g t h
your
piece
between
centers
on
lathe.
Shape
the
witha roughinggouge,
referring
to theanatomy
illustratron
on page88 for
keydiameters.
Finish
byturning
thetenons
at theendswitha
gouge(above).
sprndle
Repeat
fortheothersidestretcher.

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Turningandsizingthe middlestretcher
I
/ S i n c et h e m i d d l ea n ds i d es t r e t c h e r s
a r ea s s e m b l ebde f o r eb e i n gg l u e dt o t h e
l e g s ,y o uc a n n o td e t e r m i n teh e l e n g t ho f
t h e m i d d l es t r e t c h ebr y m e a s u r e m e n t .
I n s t e a dc, a l c u l a t e
i t s l e n g t hS
. t a r tb y c u t t i n g a b l a n ks e v e r ai ln c h e sl o n g etrh a n
y o u n e e da n dt u r n i t o n y o u rl a t h e ;u s e
. o
t h e i l l u s t r a t i oonn p a g e8 8 a s a g u i d e T
d e t e r m i nteh e s t r e t c h e r l' e
s n g t hs, e c u r ei t
i n a v i s ea n dm a r ki t s m i d d l eT. h e nm e a s u r et h e d i s t a n c ebse t w e e tnh e f r o n tl e g s
a n dt h e nt h e r e a rl e g sa, l i g n i nygo u rt a p e
w i t ht h e t u r n e ds t r e t c h egrr o o v e sa;d dt h e
r e s u l t st o g e t h ear n d d i v i d eb y t w o .A d d
another2/, inchesfor the tenonsand %
i n c ht o p r o v i dteh e p r o p ear m o u not f t e n s i o n .A d j u s at s e to f c a l i p e rtso o n e - h a l f
y o u rg r a n dt o t a la n dm a r ko f f t h i sd i s t a n c e
fromthe centermarkto eachend (right).
C u tt h e s t r e t c h et ro l e n g t ha n dt u r n a
t e n o na t e a c he n d .

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WINDSORCHAIR

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Drilling
themiddle
stretcher
mortises
inthesidestretchers
Todetermine
theangle
of themortises
to
b ed r i l l e di n t h es i d es t r e t c h efrosrt h e
youhaveto measure
middlestretcher,
the
angleformedbythelegsat onecorner
of
t h ec h a i rO
. n c et h em i d d l e
s t r e t c h ei sr
ready,placea straightedge

onthework
surface
alongonefrontandrearlegof the
c h a i ra, n da n o t h earl o n gt h ef r o n tl e g s .
Adjust
a sliding
bevel
to theangle
formed
bythetwoboards(left).Secure
theside
stretchers
in a viseandboreeachhole
w i t ht h e h a n db r a c ea n ds o o o nb i t
(nhnfn
t r , e . v t

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Assembling
thestretchers
Q
gluein themortises
J Spread
in theside
s t r e t c h ear sn do nt h em i d d l es t r e t c h e r
t e n o n sI .n s e rt th et e n o n isn t ot h e i rm o r tisesandpress
the pieces
f rrmlytogethe r b yh a n dT. h e nh, o l d i ntgh em i d d l e
f irmly,tapthebackof theside
stretcher
stretcher
mortise
witha dead-blow
hamm e rt o s e a t h et e n o nf u l l yi n t h e m o r tise(right).
Turntheassembly
overand
repeat
theprocedure.
Makesuretheside
stretchers
arebothaligned
in thesame
planes.
vertical
andhorizontal

93

neop RR)


THE CHAIR
ASSEMBLING
aregluedto
i\ lthoughthestretchers
A thelegsandthelegsaregluedto the
steps,theseprocedures
seatin separate
in quicksuccession
mustbe completed
for the chairto be symmetricalandwell
To makeglue-upgo easier,
balanced.
test-fitall thejointsandcorrectanyillfitting ones,then labelthe legsbefore
applyinganyglueto thepieces.

Oncethelegsarefixedto theseat,the
top ends of the legs are kerfed and
wedges
areinsertedinto thecutsto reinforcethejoints (page96).Thearm posts
areinstallednext,thenthearm is setin
place,fastenedto the arm postswith
The final
round mortise-and-tenons.
areinstallingthe

stepsof the assembly
spindlesand thebow (page9B).

TOTHESEAT
ANDSTRETCHERS
THELEGS
GLUING

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havebeenglued
Oncethestretchers
to the legsand the legsfixed to the

seat,it is time to trim the legsto the
shown
samelength.Thetechnique
aboveinvolvescuttingfour wood
blocksfrom a singleboard,then
notchingoneof themtofit arounda
Ieg.Placetheblockaroundthefirst
Iegto becut, then,holdingtheleg
firmly with onehand,cut it to length
with aflush-cuttingsaw.Oncethe
first legis trimmed,removethe
notched
blockand replaceit with
Position
oneof theremainingblocks.
the notchedpiecearoundthenext
legandcut it. Continuein thesame
wayuntil all four legsarecut.

mortises
in thelegs
thestretchel
1 Drilling
posrtion
on the Iegsand
thesidestretchers
I Witfrthechairtest-assembled,
onein a vise.
thelegsfromtheseatandsecure
Thenremove

marktheirlocations.
mortises
Because
thelegsarerakedto thefrontandbackof thechair,thestretcher
to
angle,
referring
bevelto thecorrect
Adjusta sliding
in thelegsmustbeangled.
illustration
on page73. Forthefrontlegstheangleis 15"fromthe
theanatomy
settheslida spoonbit in a handbrace,
rearlegs,it is 20".Install
vertical;forthe
withthebevelbladeasyou
andkeepthebracealigned
ingbevelonthebenchtop,
drilleachmortisebbove),

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