Ash

the only act of shaving I know

I’ve said it before, ‘ll say it again. I have great friends. Rick gave me an ash log last week – 8’ long. Straight & clear. One of my favorite woods, especially for chairmaking. I’ve spent parts of the last few days beginning to work up the sections into chair parts. Splitting and shaving, then more splitting and shaving. Here’s some sections waiting their turn. They don’t look it here, but the ash bolts are more than 5 feet long. (on the left side of this photo)

ash on the left, some red oak behind

I split and shaved and then bent three sets of rear posts for ladderback chairs (two in this photo). There’s more of that to come.

JA chairs-to-be

I also roughed out a set of turnings for a Windsor chair – 4 legs, 3 stretchers and 2 arm posts. Those I rived, shaved, then turned just in a general way to get them drying a bit. Then I picked through the remnants from those two jobs – to shave what’s left into ladderback rungs and Windsor spindles.

roughed out chair parts

These were all essentially leftovers – after I split out the other chair parts – so today I shaved them into 3/4″ square-sections. Random lengths. The longer stuff will be Windsor spindles. Any that already taper along their length – ditto. The stuff between 14 1/2″- 18″ will mostly be ladderback rungs. Some will be spindles. The shortest stuff there is 11″ – each Windsor arm chair has 4 short spindles. There’s more than a year’s worth for me! And the top of that heap are roughed-out stretchers for one of Curtis Buchanan’s democratic side chairs. I have the seat & legs made – but needed the stretchers. Now – big problem is where to put all this (& more right behind it). Today I committed a hideous sin – stuck them in a temporary place. On the lathe bed.

chairs & chairs

There was very little waste – a few handfuls of firewood so far. These two pieces (below) I rejected because they grew so slowly – there must be more like them, but I haven’t run into it yet. The green arrows show how the most recent growth was slower still. Weak as a kitten – if that’s really an expression.

slow growth & slower still

At the end of the afternoon, I went outside and found one more off-cut. Stupidly, I cut whatever I needed & left this piece at 14″ – 14 1/4″. If it was even 1/2″ longer it would have been perfect for ladderback rungs. As it is, some will make it, but half will be too short. But it split like a dream. I got 14 blanks from it – didn’t lose one. One piece of firewood.

perfect, but short by 1/4″

The picture below shows me splitting off the pointed inner bit. But I got one blank from that pointed side – the wood was so straight it split perfectly. (that’s how I ended up with 14, even though only 13 were marked out.)

2nd split

I’ll shave those next time. Some will make it for ladderbacks – others will be good for something.

next time

My next ladderback is going to have ash posts & hickory rungs. These posts were made long ago – the rungs are in the kiln. But I have to sort out the shop & clean it up before I can make this chair…

next ladderback

Ash – what a wonderful wood, but using it always makes me sad – millions of the trees have been killed off by the invasive Emerald ash borer – (this tree I’m working was dying from other causes if I remember correctly what Rick told me) – I don’t keep on top of that situation – but just now I found some encouraging efforts about identifying resistant ash trees – let’s hope they make it – https://www.monitoringash.org/lingering-ash-surveys/

white ash heartwood & sapwood

My Next Chair

I was going to call this one “twas in another lifetime…” just in case MR is still out there reading along. Thirty years ago I made this comb back Windsor chair. I got the details from Curtis Buchanan, I’m pretty sure it’s Dave Sawyer’s design.

1992 comb back armchair PF

I loved it then, I like it still. But a few things bother me about it. One – it survived (barely) some rowdiness that was a.) not mine and b.) part of a different phase of my life, best left in the past. I fixed it, but the fix was a bit hasty. The other points are the usual nonsense that we all engage in – pointing out the flaws of our work. Legs are too bulky and I wanted them kicked out more. But it’s still very comfortable – so one of those chairs that mocks me. I always wished I would made a new one. Well, the time has come, the time is now. I got the undercarriage assembled a couple of days ago. Ash legs, stretchers in maple & ash. White pine seat.

half way there

I bent and carved a couple of crests – doesn’t hurt to have an extra around.

white oak & ash crests

I tried to take my time with the turnings. This was air-dried ash. Slow going but I like turning ash – it’s a lovely wood.

ash legs

Here’s Curtis’ arm post in a continuous arm chair I inherited from Jennie Alexander – I aimed for this drama in my arm posts, but my pole lathe wasn’t having it. The stuff gets too whippy in the pole lathe when I try to take it so thin. But what I knew nothing about 30 years ago was old Windsors – and what I have found is the shapes/thicknesses and patterns are quite varied. So I relaxed and left my arm posts thicker than Curtis’.

Curtis’ arm post
PF maple arm posts

I’m planning on making the top half of the chair this week. White oak arm, hickory spindles. Fingers crossed.

now just stick em together

a couple of new chairs

butternut chair 2022

I built this chair a while ago, but added a linseed oil finish lately and now it’s presentable. I’ve lost track but this might be about the 6th of these chairs I’ve made in the past couple years. I’ve written before about my introduction to them through Drew Langsner’s long-ago article about one he made with his mentor Ruedi Kohler, the Swiss cooper. Like Drew, another big influence on my work was Daniel O’Hagan (1923-2000). I met him through Drew’s classes back in the 1980s. When I met Daniel, I owned a tablesaw, jointer, drill press, electric lathe, circular saws, portable electric drills, etc. I came home after one week with him and made a couple of phone calls and all those tools left my shop at once. That was 1985. I’ve never missed them.

I’ve had the chance recently to read through his old notes. Daniel wrote about these chairs in his shop notes over the years. That’s what spurred me to revisit making these European style chairs. They’re great fun to make. Just the right combination of ease and complexity.

1969 notes about German style chairs

This one is butternut again. The carving is a mish-mash, I really wasn’t concentrating on it, I just wanted to quickly fill the blank spaces. Mixing chip carving and gouge-cut carvings is silly, but my goal was to get on with the chair itself.

through tenons where the legs meet the battens and seat

When I first made them, I was following the article by Drew. At that point, Ruedi Kohler had adapted his chairs to use blind tenons where the legs met the battens under the seat. I did the same for my first several chairs. On this one, I decided to go ahead and bore those mortises through both the battens and the seats. This invites the seat to split – the battens run 90 degrees to the seat’s long fibers. The minute I assembled this one, I liked it. The reason? It looks like the old chairs I see in museum collections, etc. Maybe it’ll split, we’ll see. Some do, some don’t.

butternut with ash legs

I’m going to do a couple more with this format – the 3-piece back. It’s 2 extra joints, but only needs some narrow stock. And I like the open space in the back of the chair.

I also finished an arm chair based on the plans developed by Curtis Buchanan and Jeff Lefkowitz.

shaved windsor armchair

Although I tinkered a bit with Curtis’ details, I’m a copyist when it comes to a chair like this. This one’s got red oak arms, white pine seat and the rest is hickory. The major change I made I’ve discussed here before, I used a rectangular tenon where the crest meets the posts. Curtis’ is a bored 3/8″ hole in the post and he shaves the crest down to fit. I wanted to keep the crest full-height across the chair. That means I can’t “crown” the crest like he does, in fact it tends to droop a bit in the middle. It’s a trade I like. The crowning is more important to Curtis than the ends of the crest.

shaved windsor 2022

This is my 2nd attempt at this arm chair, (I’m sitting in the first one here at my desk) and I’ve made maybe 3 or 4 of the side chairs. This one went the best – no hassles. All the joints were tight but not so tight as to split any of those parts. It went like it was supposed to. Finally. Maybe I really can re-learn how to make windsors. We’ll see.

Curtis’ plans are here – https://www.curtisbuchananchairmaker.com/store/c8/Plans_for_Arm_Chairs.html

Some of my posts about brettstuhls https://pfollansbee.wordpress.com/?s=brettstuhl

two chairs assembled

ladderback & Windsor

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

this shouldn’t work

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.

double wedges

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.

May be an image of woodwork

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.

test drive

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/

Shaved Windsor chair; take 2

Thursday I resumed work on my 2nd version of Curtis Buchanan’s democratic chair. The first piece of furniture I assembled this year was my initial attempt at this chair back in January. https://pfollansbee.wordpress.com/2020/01/06/finished-my-curtis-buchanan-chair/

For my first Windsor-style chair in decades, I was happy enough with that one. Which is different from “I was happy with it.” One problem I had was the legs splitting at the joints.

splits in rear leg & side stretcher

I suspected my tenons were too large. I talked to Curtis about it, and if I remember right, he said because of the steep angle (say where the side stretcher meets the leg) you can get splitting. Suggested yes, make the tenons a bit smaller than I might in a ladderback chair. I was using white ash. I think another factor was the auger bit I used. It has a thick lead screw that might have contributed to the splitting.

For me, one of the most glaring problems was boring the mortises directly in the tangential plane of the legs. And the orientation of the leg is dictated by the orientation of the seat. In this case:

  • the long fibers (the “grain”) of the seat run front-to-back.
  • The growth rings in the legs’ tenons (the whole leg actually) are therefore oriented so they run perpendicular to the fibers in the seat. 
  • The leg is split so the wedge is also perpendicular to the fibers of the seat. 

This makes the front view of the front legs (and back legs) the tangential plane. And it means when boring the mortises for the side stretchers you’re boring directly into the growth ring plane. Where ring porous woods split very easily. 

BUT – I hate looking at the tangential plane of ring porous hardwoods like oak, ash, etc. And on my first democratic chair, the front of the front legs (and back of the back legs) is this plane. 

front leg shaved chair, Jan 2020

I thought about switching the leg orientation 90 degrees to the “usual” format. Then you wedge it just the same. This puts the leg’s radial plane, which changes less than the tangential plane, running in the direction in which the seat moves the most from one season to the next. So in a worst-case scenario the seat could split I guess, if it shrank a lot versus the leg tenon which wouldn’t shrink much. I think if you use a softwood seat like white pine, and hardwood legs, the seat will compress before it will split from the legs. I bet any problem would be at assembly, not afterwards. I could, of course, be wrong. It’s been a long time since I was really a chairmaker of this sort.

In the usual orientation, the leg’s radial plane lines up with the long fibers of the seat. The seat does not shrink in this direction at all; maybe the tiniest fraction of an inch. If you were to make the change I was thinking about, the radial face would now be the front view of the legs. Better visually for me, but now you’d still be boring into the radial face./growth ring plane, where ring porous hardwoods also split very easily. 

In the ladderbacks I learned from John Alexander and Drew Langsner, we positioned the posts’ growth rings at an angle to the rungs…they coined the phrase “post and rung compromise.” They didn’t make up the concept, it came from studying old chairs. The reason for it is to reduce the chance of splitting the legs when driving the rungs in – the mortises are bored between the growth ring plane and the radial plane. Below is one of Chester Cornett’s chairs, showing the front post oriented with this post & rung compromise. The radial crack bisects the angle between the front & side rungs. But you see how neither of those mortises are in the radial or growth ring plane. Some of Chester’s chairs that I saw used sassafrass posts, this one was white oak, very slowly grown.

I decided to try something this on my democratic chair #2. I was moderately successful. The legs & stretchers on this chair are also white ash, and had grown a bit too slow for this application. Too many growth rings make them a bit weak. I oriented the stretchers in the usual way – their hardwood-to-hardwood mortise & tenon joints seemed more critical to me than the hardwood/softwood leg-to-seat joints. So the growth rings on the side stretchers are parallel to the floor – those on the center stretcher are perpendicular to the floor. This means the mortises for the center stretcher are bored into the radial face, directly in the growth ring plane.

boring the mortise for the center stretcher

One side stretcher cracked slightly like on the first chair. I keep learning.  

But it was the legs that I moved around. I re-positioned them just a bit, turning them in their tapered mortises so the growth rings were angled to the fibers in the seat. The wedge, and the wedging action, are still perpendicular to the long fibers in the seat.

rear leg in the seat

This way I was boring the mortises for the side stretchers one facet off from the growth ring or radial plane.

It worked pretty well, one leg has a small split, but that might be more due to the slow growth rings than anything else. Next time, I’d choose a faster-growing log, and I might turn the tenons rather than spoke-shaving them. It’s better than first time out, almost to where I’m happy with it. 

thinking about chairs: past, present & future

I don’t need the calendar to tell me the season is changing – the light in the shop is distinctly different now, a bit lower, coming around a bit earlier. A nice time of year…

Our neighbors put out some stuff for sale by the side of the road from time to time. I wouldn’t let Maureen bring home a small table last week, so I couldn’t bring home these chairs this week. But I could photograph them…some fun stuff to see. One with four slats, but still a small chair.

A hideous knot in the rear post – ugh. But it’s lasted quite a few years.

This was my favorite of the pile. Worn down on the feet, probably was about 4″ higher I’d say.

I like the top slat of this one.

They were $20 apiece – nobody bought them. Not enough traffic these days, I guess.

I’ve had chairs on my mind lately. I told you I pay attention to Curtis Buchanan’s work. Recently I bought a set of his new drawings for the democratic arm chair.

I finished this example of the side chair earlier this year – and started another. Now I hope to finish that one and then make the arm chair.

I shaved parts for the arm chair in red oak, but mine are a bit heavy. I’ll wait a little to see how much they shrink, then will go over them just a little more to slender-them-up a bit. Or down, I guess.

Curtis’ shaved chairs really hit me right at the right time. I made Windsors many years ago, learning from Curtis and Drew Langsner. Quite some time ago, my friend Michael Burrey took me into his house to show me some things he’d bought at someone’s estate sale – including this continuous arm settee I made back in the late 1980s/early 1990s. I took one look at it, and immediately thought “I couldn’t make that today.”

and that got me to thinking about how I’d like to recover some of those techniques/skills. Then along came Curtis’ democratic chair. It reminded me of some shaved chairs I made way back when, inspired by my friend Daniel O’Hagan. Here’s a settee my brother and his wife still have, I must have made it around the same time as the one above.

This one I still use, I’m sitting in it right now – it’s my version of Curtis’ sackback chair, just with shaved bits instead of turned bits. Tulip poplar seat, cherry legs/stretchers/arm stumps. White oak, ash & hickory above the seat.

In case you’ve not got to Curtis’ chairs & plans yet – here’s his links:

https://www.youtube.com/user/curtisbuchanan52/videos

https://www.curtisbuchananchairmaker.com/store/c1/Featured_Products.html

Curtis’ plans are the inspiration for my Carving Drawings https://pfollansbee.wordpress.com/carving-drawings-17th-century-work-from-devon-england-and-ipswich-massachusetts-set-1/

 

 

Chair assembly pt 1

I spent some time recently working on the undercarriage of the “democratic” chair designed by Curtis Buchanan. First, a very modern convenience; an Ipad on the bench, running Curtis’ excellent video series on youtube, so I can follow along with what he’s doing. https://www.youtube.com/playlist?list=PLL_KlogKd1xf9GYjSfBVLKTp8KngC8q7j

 

Here, I’m set up to bore the legs for the side stretchers.

I flipped the chair seat around to get at the other legs – Curtis’ bench is in the midst of the shop, so he can get around the whole frame. I shoved some short alignment pegs in the bored mortises, to help line up the bit extension for the next set of holes. We used to use these in the JA chairs; not necessary but they don’t hurt.

I got smart & got the Ipad off the bench  – clamped it to the window frame. I got afraid I was going to smack into it. I can fix a busted chair part…but not the electronics.

Here I’m test-fitting the legs with their side stretchers in place. Gotta spring them a bit to get them in the seat mortises.

It’s been over 25 years since I made Windsor chairs with any regularity; and much of the process has been simplified since then. I spoke with Curtis last week, and we talked about how we used to bore this stuff, how to find the angles, etc. It’s all so much more direct now. The center stretcher angle he finds by setting two sticks (in my case, 2 rulers) = one across the side stretchers right above the mortise locations, the other sighted to line up with the first. Then strike a line across the seat – that’s the angle! I added a square to double-check the alignment of the two sticks.

Here’s where I got to – the rear posts are just jammed in place. I’ve caught up to Curtis’ videos. (well, except for leveling the feet) I could just bop ahead, but I might as well wait & see what he’s got up to in fitting the crest and spindles. I have plenty to do in the meantime.

This chair has a white pine seat, ash legs & stretchers. Posts are red oak, the spindles and crest I have made for it are hickory.

 

Curtis Buchanan’s new chair plans & videos

I’ve told some of these stories many times, but I’m still not tired of them. You might be. I first met Curtis Buchanan in 1987 when I was one of the students in his first class at Country Workshops. I learned Windsor chairmaking from him then, and made many chairs for about 5 years, when I veered off into oak furniture full-time and put away my scorp, travisher, reamer, sight-lines and all that jazz.

I was thrilled to bits last spring when Curtis came up to take part in our Greenwood Fest. There, he was working on a version of his “democratic” chair. The premise of this chair is two-fold – it can be made with a small tool kit; thus within reach of someone just starting out woodworking on a tight budget. And in theory anyway, it’s a building block of a chair. Learn this one & you can then go on to other more complex chairs.

He had two with him, while during the fest he made a third. I distinctly told him, “Don’t sell that green one (photo above) until you talk to me first…” On the last afternoon of the event, I was running around the site seeing to some of the tasks involved in winding that thing down. Didn’t get to Curtis til some time had gone by. Both chairs were gone. I asked what happened? “Oh, I sold both of those chairs…” just as matter-of-fact…turns out he cautioned the buyer that I might come for the green one. I did. Here it is again:

 

But now I can make my own. Curtis has just released a new set of plans; and a new video series. In the spirit of the democratic notion about this chair, he has set up the plans so that you can either buy them for full-price, or you can download them and pay what you can afford. He leaves it up to you. The full-sheets version is excellent; if I was buying them that’s where I would go. The chair is shown half-scale; the seat, legs, spindles and stretchers, bending forms are all full-sized. https://www.curtisbuchananchairmaker.com/store/c1/Featured_Products.html

 

 

here’s one of his latest versions:

 

here, he’ll tell you about the chair, then hunt down the youtube channel for him. He’s posted the first 4 videos for it, with more to come.

https://www.youtube.com/user/curtisbuchanan52/videos 

I made a “shaved” (not turned) Windsor chair 30 years ago; still have it kicking around, but it got bumped from the kitchen table when I inherited one of Curtis’ continuous arm chairs from Jennie Alexander. I made it based on Curtis’ sackback plans, but substituted shaved cherry legs, stretchers and arm posts. I got the idea from our friend Daniel O’Hagan who had one or more shaved Windsor chairs when I visited him in that era. This chair is cherry, tulip poplar, ash, hickory and white oak. When new, they looked very different, but 30 years of use have blended the colors pretty well. Patience.

Similar colors the other day in this view of a red-tailed hawk hunting over a marshy area nearby.

“I got it second-hand…”

I keep showing up on the second-hand market! I started making furniture between 1978-80. That’s closing in on 40 years…which is a lot of furniture. During the past few years, I have heard of/seen a number of chairs I made showing up in antique/collectibles shops, auctions, and even one at…well, you’ll see. Here’s a couple examples –

This continuous arm settee I made back in 1992. A friend bought it not too many years ago, along with a windsor rocking chair, in a house-moving/divorce sale (I think). I wish I had known, I’d love to have this settee – I doubt I could make it again…but I know it’s appreciated where it now resides.

 

This next one I did buy, and sold again. I had it in my shop for years, a fellow called me up one day asking if he could buy it & he did. Then a couple years later, another friend called me to say one of my carved chairs was in an auction in Maine. I eventually got it through the auction, and called a couple who has collected several of my carved pieces. I offered them this chair at a reduced price, and they said they’d love to, but were out of room. An hour later, they called back & said they made space.

wainscot chair

 

Another wainscot had a slightly sad story to it. I made it at the museum as an award (I was the awards department for quite a while) – for our former co-worker Karin Goldstein. Sadly, Karin died quite young, from cancer. Just shy of 50 maybe. When she died, she had no local family, and some of her stuff ended up in a local shop. Another friend saw this, called to confirm it was my work, and ended up buying it for his wife, a good friend of ours, and of Karin’s. So a semi-happy ending.

This week I got a note from another friend who found a chair “made by the guy at Plimoth Plantation” – well, sort of. I was there for 20 years, but I made this chair well before that – I’d say late 1980s, maybe into 1990/91. She got it for $45. Even I could afford that!

The last one in this batch has the best story. Found at the swap shop in the Hingham, Massachusetts town dump! $5.00. A friend got it after some tussling with other dump-shoppers, and gave it to us.

I made a lot of chairs, but way more carved boxes – where are my carved boxes? Maybe they’ll be out on the 2nd-hand market in a few more years…

Chairs

cod 2003

At my house, the carved joined stuff is in every room. I have tried many times, and always failed, to count the pieces of furniture in this 4 1/2 room house. You’d be amazed at how much stuff you can cram in here. (I’m in the kitchen right now – 9 pieces of free-standing furniture, 3 hanging on the wall, and all the built-in cupboards above the counters)

 plain chair

This week, I have been making this little, big rush-seated chair. Little because it’s a low seat, generally small-size chair. Big because it’s not subtle – the posts are almost 2” square, the rungs fit in holes that are 15/16” in diameter. So little big chair. It’s based on 17th-century chairs that we mostly know from Dutch artwork, more-so than from surviving examples. (next up for it is trimming the posts here & there, weaving the seat…) These are ancestors of the ladderback chairs that I first learned back in the late 1970s/80s. Here’s one that I did about 1984 or so. A more recent kid’s version too.

ladderback

kids

 

I began as a chairmaker. Made ladderbacks, rockers, Windsors – then got into the 17th century & made wainscot chairs, 3-legged & 4-legged. Turned chairs ditto. Leather chairs. Chairs w boxes in the seat. Kid’s chairs, high chairs. My semi-latest chair was the walnut brettstuhl.

But at our kitchen table, the chairs we use at every meal and then some are Windsor chairs I made 20-25 years ago.

c a chair

At my desk too. I once had one of those stupid office chairs, then I came to my senses & remembered that I am a chairmaker. Windsors are lightweight, comfortable, attractive. Sturdy. Fun and challenging to build; carving, turning, shaved work, sculpted seats. good all around projects. And so much variety.

Two things happened this week to remind me of how much I like good Windsor chairs. Lost Art Press announced the release of Pete Galbert’s long-awaited book on Windsor chairs. You already know about that…

One of the days that the mail got through here, I received Curtis Buchanan’s next installment in his printed plans for his chairs, this one a fanback side chair, one of my favorites.

Curtis Buchanan fanback side chair

c b plans

I learned Windsors from Curtis, starting in 1987. I really like his approach, both to his chairs and to his life. If you’ve seen his youtube series on making a Windsor chair – then you’ve seen Curtis’ style, very human, simple, direct – and he makes especially beautiful chairs. This set of plans is 4 pages; some 1/2 scale, some full scale. Two different turning patterns, bending forms, seat profile & plan. Boring angles – a course in Windsor chair making in 4 pages. I’m ordering Pete’s book, but I’m keeping Curtis’ plans too – you never know when I might reach into my past & make some more chairs. We must be able to squeeze one or two more in here…

links:

Curtis’ plans & videos http://www.curtisbuchananchairmaker.com/store/c1/Featured_Products.html

Pete’s book: http://lostartpress.com/collections/books/products/chairmakers-notebook

my wainscot chair video  https://pfollansbee.wordpress.com/book-dvds/