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I built a prototype of a Morris-inspired outdoor chair this during the last week. The chair wasn't supposed to be a prototype but I made a major goof on the chair, so I am keeping it for us. I decided on a week ago to make two of these All-Weather Morris chairs for our daughter Kristel for Christmas:
The plan and the article about making the chair are by David Theil in the book 'Arts and Crafts Furniture Projects' as published by Popular Woodworking. Beside the picture, you see my parts cutting plan.
There is a striking similarity between this chair and a "real" Morris chair with photos and plans in the same book:
Some day, I hope to tackle making the real chair.
The plan called for construction out of 3/4 inch thick pine. But, I decided to use 1 inch thick (5/4 dressed) western red cedar instead. When I picked up Margaret from physical therapy Monday at noon, she was very surprised to see a load of 16 foot long 5.5 inch wide, 1 inch thick cedar on the roof rack of the car. I drove very slowly and carefully. Here enough of the wood for two chairs and two stools is sitting just outside my woodworking shed:
The plans call for 71 parts in a chair and stool after cutting all these parts (as well as 10 more that I found I needed (but more on that later)) most of the edges were rounded over on my router table using a with a 1/4 inch roundover bit then sanded with 80 and finally with 120 grit paper. Here one part is about to be sanded:
The four legs were made as Ts using screws glue and simple butt joints. In fact, all the joints in the chair and stool are butt joints. David Theil only glued and screwed a few of the joints in his chair and used a brad nailer on the rest. I glued and screwed all the joints.
The top of the back legs were cut at a 5 degree angle, started on the table saw then the cuts were finished by hand:
The top edge of the stretchers had to be cut at an angle and my guided circular saw made this an easy task: