Before I started weaving the backrest, I made a final check on the cords-per-inch with the actual cord I would be using. It turns out my original numbers were off slightly. If I packed the cords tightly together to eliminate gaps, there were 7.27 cords-per-inch, not 7. For the seat, this required me to mark and drill new holes for the L-nails. I made a marking jig with the new nail spacing to make it easy to mark the new locations.
With the new locations marked and drilled, I could begin installing the L-nails.
One rail done.
The nails on the side rails are more tightly packed for the weft cords.
I start by wrapping the front rail and at each nail, sending a pair of warp cords to the back rail.
As I got close to the opposite side, I covered the side rail nails with a shop rag to prevent them from catching the bundled cord as it was passed through the gap when wrapping the front rail.
Once the front rail was done, the wrapping continued on the back rail to fill the gaps between the warp pairs.
When the wrapping was done, I angled the head of the L-nails to capture the wrapped cord where it jumped over to the next gap.
Finally, it was time to weave the weft. What's nice about this step is that it can be done directly off the spool, so it's one continuous length of cord.
After the last row, I could up-end the chair and hammer in all the nails.
For the leg tips, I cut some leather disks for pads. I used a Sharpie to blacken the edges to match the chair. These were attached with some contact cement.
A backrest pivot can now be installed into the pre-drilled holes. The second pivot is screwed in after the backrest is in place on chair.
With the backrest installed, one chair is done. Well, nearly done - the one thing remaining is the leather strap that limits the backrest travel. I still have to weave the other chair, but I'll consider this project complete. Thanks for following along!
Wow! Sharp looking and elegant. Have enjoyed following along here on the side. These chairs will spread quality and elegance to any room you put them in. Congratulations
"The good chair is a task one is never completely done with" Hans Wegner
Thanks, guys, I appreciate the comments. Splint - nice confiscation of that old joke. 😄
The chair is comfortable, but very firm. I'm not sure it's going to supplant the Z-chair as my "Archie Bunker" chair (for those of you of sufficient age and familiarity with American TV). But, I'm pleased with how they turned out and will find a good place to display them (and use them). I'll make a project post when all the final bits are done.