As mentioned in the last post I started another settee, # 4. This will be the fourth one in three years. I want to make a few a year really one a month would be cool. They take about sixty hours to make. It’s very old school, the rout I take to achieve this.
I use the table saw, band saw and planer some but the majority of work is detail work.To me detail work involves hand tools and there are a lot of parts to these guys so your going over each piece a few times with different tools. I like this process, you start with the freshly cut tree, split out and prep your parts. Its the best when I have a surplus of stuff roughed out and dried down then its like going to a stocked kitchen and mix and match or come up with something different all together.
That said I am always open to speed the process up with out loosing much of the connection that doing things without power tools gives you. keeping it real to what it is, made from our natural surroundings to aid in our everyday to make us more comfortable and close to our natural surroundings.
I had some stainless steel plate cut for me over the summer to use on the boat where the outboard motor through bolts the transom.The washers and nuts were stressing the fiberglass too much and the force needed to be spread over a larger area. These pieces are to thick , had to go with thinner stock and it worked great, better than the thick 3/8″ ones would have. Expensive mistake so I’m glad to use the stuff up.
The tenons for the back spindles are 1/2″ in the seat and 3/8″ in the crest, there are 19 of them and its very time consuming fitting them with the spoke shave. By drilling a hole in the metal plate and then pounding with a heavy mallet the same size as the hole spindle( like a 1/2″ square) through a 1/2″ hole you get a dowel the size of the hole in the plate. I worked ok for the 3/8″ tenon but the 1/2″was still to big. Better too big than small. I drill with a brace and the bits I use are Irwin, they are a little bigger than a standard drill bit by a 32nd. the twist drill was 1/2 if I pounded them they would be loose so I made those at the shaving horse. It’s a good reference point to work from and that speeds thing up but isn’t the silver bullet to a perfect tenon every time. Just need to fiddle with other drill bits.
If you use hand tools regularly you need to sharpen a lot if you sharpen a lot you need to flatten your sharpening stones a lot. I have struggled and wasted time and stones throughout the years in the flattening process.Last year I bough the DMT lapping plate and it has saved me so much time, energy and most of all frustration, sharpening isn’t such an ordeal anymore. Cris Schwarz posted about his an you know it gets a workout.