I got two chairs assembled recently – a couple of days ago it was the ladderback on the left – for some photos we needed for JA’s book. Today’s was the arm chair version of Curtis Buchanan’s Democratic chair. https://www.curtisbuchananchairmaker.com/store/p40/Full-Scale_Drawings%3A_How_to_Make_a_Democratic_Arm_Chair.html
Once you have the undercarriage assembled, it really shouldn’t be able to then fit in the tapered mortises – but there is enough flex in the structure to pull the legs apart, so it can all go together.
I saw Elia Bizzarri wedge the chair legs with two wedges in the video series he & Curtis did of the side chair. First you open up the top edge of the mortise fore & aft, I used a round file. Just a bit. Then you split it twice and drive the wedges in. Easy does it though, you can shear off part of the tenon if you try to spread it too much. Below is a test joint I made a few weeks ago & cut open to peek inside. That hourglass shape won’t come back out.
It turns out I’m a lousy student – I changed the crest rail tenon – and I did the arm-to-rear post joint differently from Curtis’ plan too. I bored a tapered through mortise in the post, and put enough slop in the tenon on the back end of the arm so I could get it installed into the rear post and down onto the front arm post. Then wedged it from behind (& above.)
The nice thing about making Windsor-style chairs is you don’t have to wait to sit in them. As soon as they’re assembled, you’re done. Next week I’ll have to weave a seat on the ladderback.
this is the chair that didn’t want to happen – but I kept at it. https://pfollansbee.wordpress.com/2021/01/11/i-thought-you-were-supposed-to-be-good-at-this/
And here’s the crest rail joint, on a side chair I made earlier – down in the middle of this post – https://pfollansbee.wordpress.com/2021/01/10/some-shop-work-today/