A Frankenchair #3: A Curvier Approach

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I spent a lot of time online looking at images of mid-century modern chairs looking for inspiration for the base.  I kept coming back to this recliner by Vladimir Kagan.  I liked its overall fluid lines, and the legs and canted back stretcher seemed perfectly suited for what I want to do.   


I sat down and made a rough sketch the side section and then modeled it full size in OnShape.   After a couple revisions to adjust the shape and proportions, I made a final paper template to attach to some lauan.
 

I recently scored a nice stack of white oak on FB Marketplace for $100, some of which I planned to use for this project.   I felt confident enough in the design to go straight to finish material and bypass the prototyping.  If I screw-up, I haven't lost much.  I picked a couple of pieces, surfaced them, and laid out the placement of the side pieces.  The extended rear leg had a grain pattern that somewhat followed the curve of the leg.


Rough cut out on the bandsaw.


Trimmed to final shape on the router table, avoiding the tips of the legs and the joint edges.


I created a couple sleds to cut the joint edges on the table saw.   The sled for the front leg would ride against the fence.



The sled for the rear leg would ride against the miter gauge.



The stop block on the miter gauge ensured a consistent cut for both rear legs.  I cut front legs on the left side of the blade and the rear legs on the right.  Any discrepancy in the blade angle would cancel out when the pieces are joined.


I created a caul to provide a clamping edge that was parallel to the joint.  The caul was lined with a strip of sandpaper to keep it from slipping.   This worked, but in hindsight, I should have created a little hook at the end of the caul to index the end of the leg.  Or, left some excess on the leg for a built-in clamping stub.


I made some domino stock out of some of the scrap white oak.


I planned to use the maximum depth of cut on the Domino (28mm) for the floating tenons, and made some non-standard-length tenons to match.




Dry fit before glue-up.


Finally, glue-up.


The next day I sanded down the excess left around the joints to blend the curves.


All of the remaining shaping will wait until after the mortises are made for the stretchers.


With a temporary stretcher clamped between the leg assemblies, I could set the chair shell in place to get a sense of how it will look.  I like this much better than the initial prototype.    It does look a little chunky for the size of the chair (pendulum swings in the other direction), but I think some of that will go away once all of the edges have been rounded. 


Next, I need to play around with how the side assemblies will be oriented relative to each other - separation, splay, etc.  Goody, more compound angles.   😆

15 Comments

i love your evolution of design. youve become quite the master at these style of chairs.

working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

Masterful!
Those jigs are the cats meow, or maybe if you made the chair into a form of rocker, any outdoor cats yeow!
I like that a lot.

The more I looked at the scoop in your previous post, the more I thought about manta rays, and I wondered if more organic shapes (possibly something inspired by a sea creature or plant) might suit the chair better. The curved legs feel very appropriate.
I like the way you’re building it. The best way. 

James McIntyre

Patient and clever. Did you already have the fibreglass seat Ross or once you settled on the design you went and found it?
Love following your projects.

Kerry - Working with wood, the smell the feel, is such a joy, its a meditation of sorts.

And if I'd read 1 & 2 I'd have known the answer to my previous question. Who'd have thunk it, a hot tub corner. As I said clever......

Kerry - Working with wood, the smell the feel, is such a joy, its a meditation of sorts.

Thanks for the write up Ross!  It's really interesting to get a peek into other people's design processes 😃  I really like the chair you chose for inspiration.  Looking forward to your finished take on it!

 Pottz
 commented about 14 hours ago
i love your evolution of design. youve become quite the master at these style of chairs.
Thanks, Pottz.  I can't claim master, but I'm definitely an enthusiast. 


 SplinterGroup
 commented about 13 hours ago
Masterful!
Those jigs are the cats meow, or maybe if you made the chair into a form of rocker, any outdoor cats yeow!
I'm sure I could have managed those 4 cuts without jigs, but you just can't beat them for repeatability.   When they're just made from scraps, all the more reason to make them.   Funny you should mention a rocker - that's been on my mind lately.  Perhaps a future project if no cats will be harmed.  :)


 Ron Stewart
 commented about 12 hours ago
I like that a lot.

The more I looked at the scoop in your previous post, the more I thought about manta rays, and I wondered if more organic shapes (possibly something inspired by a sea creature or plant) might suit the chair better. The curved legs feel very appropriate.
Thanks, Ron.   You know, I think I'd make better progress on design if I was more skillful at making those kind of observations.   You've got the knack.  


 James McIntyre
 commented about 11 hours ago
I like the way you’re building it. The best way. 
Thanks, James, I think you're right.


 Aussie Larks
 commented about 3 hours ago
And if I'd read 1 & 2 I'd have known the answer to my previous question. Who'd have thunk it, a hot tub corner. As I said clever......
Thanks, Aussie.  Now that I've started, I just have to make at least one of those salvaged hot tub pieces into a chair.  Maybe a mix of patience and OCD.  :)


 HokieKen
 commented 42 minutes ago
Thanks for the write up Ross!  It's really interesting to get a peek into other people's design processes 😃  I really like the chair you chose for inspiration.  Looking forward to your finished take on it!
Thanks, Ken.   Yeah, that Kagan chair is something - only 50 ever produced, I read.  It definitely got my gears turning.
A very enlightened series I must say.  Taking an old tub, and turning it into a chair with a great style is just awesome.
I love recycling.

Madts.

Tor and Odin are the greatest of gods.

It's fun to watch this project evolve!
I like all your writeup Ross. Well done. The Frankenchair approach is an excellent approach. Awesome!!

 Madts
 commented about 11 hours ago
A very enlightened series I must say.  Taking an old tub, and turning it into a chair with a great style is just awesome.
I love recycling.

Madts.
Thanks, Madts.  This one is a fun challenge.


 Steve Rasmussen
 commented about 10 hours ago
It's fun to watch this project evolve!
Thanks, Steve.  I'm happy to have you along for the ride.  :)


 MrRick
 commented about 8 hours ago
I like all your writeup Ross. Well done. The Frankenchair approach is an excellent approach. Awesome!!
Thanks, Mr. Rick, I appreciate it.  
Way better than the first prototypes. Bold, yet fluid lines, this look realy promising - and I sense a more personal design language emerging

"The good chair is a task one is never completely done with" Hans Wegner


 Kaerlighedsbamsen
 commented about 7 hours ago
Way better than the first prototypes. Bold, yet fluid lines, this look realy promising - and I sense a more personal design language emerging
Thanks, Ty.  I think this is the first chair I've built that wasn't an attempt to replicate another's design.  I'm good at the engineering, but I need to develop better design skills.
This is an important step to take; to go unknown places. I am realy exited to see where this is going when you first start that process

"The good chair is a task one is never completely done with" Hans Wegner