Shaker Bench II

My previous post was on a project I recently made off a plan of a Shaker bench.  The author lengthened the bench and added a backrest.  If you refer back to that post you will read how I battled with the three way assembly due the sequence given in the plans.  So I decided to redo this bench the way I thought was more logical and of course easier to do.

I decided to leave the backrest out for a number of reasons.  I didn’t have enough wood, I was remaking this bench just to try and find a better way to assemble the sub-assembly which didn’t involve the backrest, and the original Shaker design did not have a back rest-par for the course for these ascetic people I suppose.

In fact I only had one plank of Poplar and one plank of Kiaat  (Pterocarpus angolensis) available.  So I decided to use the bland Poplar for the underside (legs and seat supports),  and the rich-grained Kiaat for the seat.

I started by cross cutting the Poplar plank to length with my radial arm saw-4 pieces for the legs and the remaining long piece for the seat supports.

20131103_170501c 20131103_170520c

Above photos show single Poplar plank cross-cut into 4 short pieces (2 each per leg) and one long piece for the 2 seat supports.  The first photo shows the some offcuts sitting on the saw-bench underneath which are kept for testing the finish.

The pieces were then jointed and thicknessed.  My son developed an ingenious way to hold the dust extraction hose from getting in the way of the thicknesser outfeed table.  Basically an elastic tie attached to a tensioned cable at ceiling height:

20131103_195602c 20131103_195633c

Then the bench end pieces which make up the legs were glued together:

20131103_230039c

These end pieces then had an arch cut out of them to form two legs and they will then be lap-joined to the seat support.  Again see the previous post for more on this.

20131106_205738 20131106_213937

After the legs/side pieces were cut out, they were joined to the supporting seat supports. The lap joint was cut with a tenon saw and only a dry fit was done.

20131224_21273020131224_212741

In the above photo you will notice that only the the seat support to your right has been joined.  You will also notice in both pictures how the seat support is not flush with the top of the leg/side piece, but is recessed by 12mm.  The part of the leg/side piece sitting proud will fit into a dado that will be cut into the underside of the seat, hence the three way fit that I referred to earlier.

Now we come to the part where I differed in my order from the previous bench.  Whereas the previous bench’s instructions called for the dado to be cut into the seat support first, I now took the whole dry fitted sub-assembly pictured above and laid it onto the underside of the seat.  I then marked out the dado directly and cut them.  This seemed liked the more logical (& esier way) to do things.  In reality it was much easier.

20140329_152807 20140327_185344 20140327_185322

I also added butterfly or dovetail keys on the seat for effect.  I made them from the same wood type so as to lessen the contrast. I placed four in a row along the centre line, two larger ones on the outside and two smaller on the inside. I used the Rockler jig to cut them out.

20140322_233447 IMG-20140325-WA0000 IMG-20140325-WA0004 IMG-20140325-WA0006 IMG-20140325-WA0010 IMG-20140325-WA0014

Kiaat tears out very badly so I quickly gave up on the handplane and continued with the #80 scraper. I mixed fresh orange shellac and applied 5 coats with a brush and finished with one coat of diluted poly.  The shellac decreased the contrast between the light Poplar & darker Kiaat.

twin bench c 1 twin bench c 2 twin bench c 3 twin bench c 4

Advertisements

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s