Wegner Dolphin Chair #11: Middle Backrest Rail Prototyping

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This is part 11 in a 11 part series: Wegner Dolphin Chair

  1. Four years later
...
  1. Arm/Seat Rail joint
  2. Middle Backrest Rail Prototyping

The original chair has top, middle, and lower rails that connect the two backrest stiles.   In addition to providing additional stability, I think that a big reason for the existence of the middle rail is to provide a landing point for the vertical caning of the backrest.   If there were only a top and bottom rail, the natural path of the caning between the two rails would have gone way outside the curve of the stiles (green line below).   The middle rail would have provided an intermediate anchor point for the vertical caning to bring it closer to the desired curve of the backrest.



My middle rail needs to serve a similar purpose for the vertical warp cords of the Danish weave.  I used a scrap of white oak for a proof of concept for the idea I have for the rail.   Basically, the rail will have a series of holes along the front edge, each large enough to pass a pair of warp cords.  I spaced the holes so that the gap between adjacent pairs of warp cords would accommodate 5 wraps of cord.  I also make one hole large enough to accommodate 4 warp cords.  On the prototype, that hole is centered, but on the actual rail there would be one on each end of the rail (if I decide I want to have a border of 4 cords).



I put a 1/4" radius round over on the edges and a 1/8" radius round over inside the holes.  Here, the prototype rail is set inside the remnant of the scrap it came from just to provide more support for the router base.


This is roughly where the middle rail would be located on the stile.


Verifying the fit for two warp cords and 5 wraps.


Fully wrapped.


I used 1/4" crown staples the tack down the cord.  None of the fasteners would be visible on the finished chair.  Only the curved edge sides would be visible.


The spacing seems good on the back side of the rail.


And this is how it would look on the front side of the rail.  The vertical wraps will be a noticeable transition between the horizontal weft weaving above and below the rail.   Hopefully, it won't be too visually jarring.


After I got to this stage, I realized that I forgot to account for the additional interior slot that will be needed on each rail.  The slot provides an alternative path from top to bottom, which allows the warp pattern to be different on the back than on the front.  Below are pics from an earlier project where I used this technique.  The wider band of warp cords on the back provides a hiding place for knots when joining lengths of the weft cords while weaving the backrest.  I need to go back and look at the prototype rail and see how best to accommodate the slot and still be able to wrap the rail as shown above.

Thanks, Splinter.

I removed the cord over a section of the rail and made a 3/8" wide slot.   The wide slot allows me to make abbreviated wraps of the front and back of the rail and leave room for the hidden internal warp cords later.   There's not a lot of meat around the holes, so I need to be very careful about positioning the stapler to avoid a blow out. 





I used individual pieces of cord for each of the two short wraps, so there are extra ends due to the patching.  When wrapping the actual rail, I should be able to wrap more optimally, with fewer loose ends.