The
Construction Process
The first step in the construction process of a
Windsor chair is steam bending the arm and the bow. Using freshly
cut Red Oak from Maine I carefully shape these parts to stay with
the grain of the wood giving the finished bow and arm strength to
support the top of the chair. Once they are bent into a horseshoe
shape they are set to dry for approximately two weeks.
Spindles for the back of the chair are also made from freshly
cut Red Oak. Using a drawknife and spokeshave I hewn the spindle
down to its unique 18th century form. Each spindle takes on a special
character of its own, making the piece “one of a kind”.
The seat for the chair is constructed from a
2” thick plank of clear Eastern White Pine. As I chop away and
remove excess wood with a gutter adz, the “saddle” of the seat
is formed.
Several other tools including a compass shave, scorp, and travisher
complete the saddle to make an extremely comfortable fit for the
person sitting in the chair.
The front of the seat is carved out at a steep angle to make it
appear as though it is thinner than it actually is. This is one
of the unique characteristics that set my chairs apart from the
mass produced factory chairs.
Special care is taken to ensure good proportions, design and strength.
One distinctive aspect of my chair making process
involves drilling every hole completely by hand. Holes that are
drilled into the seat are corresponded with a device called a “tapered
reamer”, that forms a tapered lock in which the leg is set. This
is an exceptionally strong joint, and the more the chair is used
the tighter these joints become. All of the legs and spindles are
split at the top and wedged to avoid the leg or spindle from pulling
or twisting out.
The final assembly of the chair once completed works similar to
a suspension bridge. Just as the last spindle is placed through
the bow, the joints of the chair form tight and perfect fit.
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