Because my seat frame components are probably not quite as thick as those in the original, I compensated by making mine slightly wider an limiting the edge round-overs to 1/4" radius. That radius will be fine for the Danish cord that will wrap the frame and preserves the strength that would be lost with a greater radius edge. All parts received a round-over on all edges, avoiding those areas on the main stretchers where the secondary stretchers join.
The ends of the main stretcher were trimmed back to allow for a slight reveal where they meet the legs.
I'll complete the final shaping of the frame after the secondary stretchers are glued in place.
Before glue-up, I used a card scraper to remove all of the pencil layout lines.
Strap clamps were enough to pull the joints together for the glue-up.
I dry-fit the frame into the arm/leg assemblies to let the glue dry with the frame in-situ. (You can see in this photo the finger joints have been pared back flush.
Thanks, guys. Splint - I was careful to keep grouped parts in different areas of the shop to prevent mixing them up. I did still leave some marks to indicate which assemblies go together for a particular chair. Belt and suspenders.
With the glue dried on the seat frames, I took them back to the bench to blend-in the ends of the stretchers with a round file, card scraper, and some sandpaper.
Really nice work, can't wait to see the final result.
Doesn't it often make you wonder just how they did all this in a production shop? I assume they had custom made jigs for every step of the process. And even with that, the glue-up would probably be the biggest challenge.
