I recently got a text from a neighbor (Ashley) saying: “No rush, were not entertaining any time soon but we would love to have our dining room chair repaired.” To which I replied, “How broken is it…?” It was really broken with a vital section missing. I figured I could not make it any worse.
I started early Saturday morning and finished it on Sunday I’m happy to say that it’s standing on its own 4 feet. During the build I came up with some new techniques and did some drastic cuts which meant some drastic rebuilding. Look in the gallery for notes on how the build went, as I tried to document each step.
Chair as received Ethan Allen, all hard wood construction saw guide to cut off the broken leg section used a pull saw with guide oak board that will replace the top section of the leg cutting to size glueing up interesting clamp to hold leg in place cutting off the top section of leg cutting 45 degree slot finished top section now to join with leg cut the mortis with the dominio matching mortis dry fit the mortis and tenon glue up (overnight) all attached cut a mortis in the leg (note how the orginal build used dowles) matching mortis (this took time to line up) glue more glue used a mallet to drive in clamped up 4 hours I could only mortis and tenon one section the side rail would need another method trip to Woodcraft to get a Kreg Jig drill and bit wouldn’t fit so run to Lowes for the 90 degree two important holes needed two new tools mahogany stain it stands, note the broken section on the bench
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