Back Slats

The five back slats have the same curve as the upper part of the back legs.

lay 01t shape. Start by cutting oversize blanks from lW'-thick stock, see Fig. 3. (Three blanks are needed—two slats can be cut from each, giving you one extra slat)

Then transfer the curve of the top of the back leg — front edge only — to this blank.

Is 4" ^ BANDSAW

BACK SLAT ALONG

BLANK (3 NEEDED) FRONT CURVE

Is 4" ^ BANDSAW

BACK SLAT ALONG

BLANK (3 NEEDED) FRONT CURVE

lay out shape. Now transfer the leg pattern to one of the blanks. (Enlarge the grid pattern to actual size, or, for a set of full-size patterns, see Sources on page 31.)

lay out mortises. Before cutting the leg to shape, it's easiest to first lay out all the mortises. Then drill the mortise in the edge for the side seat rail (while the opposite edge is still straight). see detail on the leg pattern and also Fig. 1.

first leg. After the mortise is drilled, I cut the first back leg (A) to shape in two stages. First, I bandsawed the curve to within W of the pencil lines. Then I sanded up to the pencil lines to smooth out the curves.

second leg. Now transfer the shape of the first leg to the blank for the second leg. G used the leg itself, not the pattern.)

Also transfer the location of all the mortises. Then drill out the mortise for the side rail, see Fig. 1.

Now the second leg can be bandsawn to rough shape and sanded to match the first.

drill mortises. When both back legs are sanded to the same shape, the remaining three mortises can be drilled on the side of each leg, see Fig. 2.

handsaw. Now band saw to within Vi6" of the pencil mark, then sand the curve smooth up to the pencil mark. To cut each of the five back slats (B) to the same shape and thickness, I used a pointed rub block on the band saw table, see Fig. 4.

To use the rub block, first clamp it Vi6" from the side of the blade. Then, push the workpiece through the saw with the curved front edge of the workpiece sliding across the point of the rub block. This slices off one of the back slats like a slab of bacon.

thickness sand. When all the slats have been cut out, sand them to finished thickness (V4"), see Fig. 5. Then rout a Vfc" round-over on all four edges.

DRILL MORTISE

FRONT EDGE

OVERSIZE

DRILL MORTISE

FRONT EDGE

OVERSIZE

FRONT EDGE

PATTERN FOR BACK

• ALL MORTISES ARE DEEP

NOTE:

• TRANSFER PATTERN TO 11/2"-THICK BLANK

ALL SQUARES 1- x 1"

MORTISE FOR SIDE RAIL

f" 2Vj"

FRONT EDGE

PATTERN FOR BACK

• ALL MORTISES ARE DEEP

NOTE:

• TRANSFER PATTERN TO 11/2"-THICK BLANK

ALL SQUARES 1- x 1"

FRONT FACE

f" 2Vj"

MORTISE FOR SIDE RAIL

CLAMP RUB BLOCK S/16" FROM BLADE

CLAMP RUB BLOCK S/16" FROM BLADE

AFTER SANDING, ROUT »v ROUND-OVER ON EDGES

CLAMP RUB BLOCK V4" FROM DRUM

3" DRUM SANDER

CLAMP RUB BLOCK V4" FROM DRUM

3" DRUM SANDER

AFTER SANDING, ROUT »v ROUND-OVER ON EDGES

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  • robin
    How to cut out rocking chair legs?
    8 years ago

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