Glue-up was simple enough - a couple strap clamps and one bar clamp over cork pads to pull the joints tight for the back stretcher.
Before final fitting, I rough-sanded the entire bottom of the chair shell, and used a rotary tool to remove the remaining white junk down in the cracks.
My wife liked the visual texture of the sanded fiberglass, so I might just finish it with a clear sealer rather than paint.
I installed a pair of stainless threaded inserts on the risers of the front stretcher. They're pretty lightweight (for M4 screws), but they don't need to provide any strength, they just keep the shell in position.
With the shell held in position by the two front "shoulder washers", I marked locations on the outside of the shell where it rested on the back stretcher. From there, I could inset slightly the position for two more screw holes. After removing the shell, I drilled the holes from the outside of the shell.
With the shell back in position, I could drill back through the two holes into the stretcher.
The screw and the stretcher are tilted at different angles, so I offset the stretcher holes to one side to avoid blowing out the bottom of the stretcher when drilling. With the screw holes enlarged, I installed the threaded inserts.
I added a countersink on the seating side.
Fully assembled and ready for finish.
The future owner taking a test sit. I got the seal of approval.
Neat looking assembly and a nice detail using machine screws. The low profile, "lounge feel" goes well with the wide seat. Like the view from the front, the broad curve of the seat and angled legs looks great together - and best of all, the new owner seems satisfyed
"The good chair is a task one is never completely done with" Hans Wegner
I like it when people actually show their projects in use. I think it’s to nice to put out in the elements. If it were mine I’d have it professionally upholstered. Or do it yourself.
Steve - thanks. It's been both fun and a little aggravating at times. Working with an asymmetric shell involved more fiddly fitting than I'm used to.
WoodGuy - Yeah, I'm thinking this chair may not live outside. That would get me back on familiar footing with respect to finishing. My wife has volunteered to make a pad for the chair, but I wonder if the curved surface will present some challenges. We'll see.
Ross I was at an upholstery shop today and the owner Glenn was working on an egg chair by Arne Jacobsen. It reminded me of your chair. I took photos of it. He said the structure under the upholstery is made from fiber glass. He had to import the foot rest from Holland.
He also works on Stickley, Malouf, and restoration of Blacker house furniture. He showed me a photograph of this chair by Malouf he upholstered.
james it's "maloof" not malouf ! i just like my heros names spelled properly ! that was the last piece that sam personally designed right before he passed away. i got to see it at his shop. our member sammarine recreated it very well.
working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.
James - Again, I didn't build the egg chair, I bought it. I got mine from https://www.modernclassics.com. They have some quality reproductions of some classic MCM furniture. I also have a Knoll loveseat from them, and I have been pleased with the quality. Not the cheapest reproductions, but less than the originals.
