The story of 9 sculpted wood bar stools

The story of 9 sculpted wood bar stools

chair seat clamping

First up in the chair building process is cutting to tenth and width the wood pieces for the seats. I try to always do a 2 board seat giving the most visually pleasing grain patterns especially after grinding and shaping the seat. Now  when clamping 2'' material lots of clamp pressure is required, I think I used every clamp in the shop!

remove glue scraper

Im using my cabinet scraper to remove the excess glue, you can see the cabinet makers triangle I draw on the seat blank when organizing the pieces before glue up, this help keep everything in order and glued to the piece it should be.

cherry glue up scraper

This will be one of the 2 cherry seats i'm doing, they are going to be beautiful not just from my work but from what nature has given up.

table saw riving kneif

The seat blanks need to be trimmed to length, I do this using my "flying dutchman" or table saw sled, this is a great tool that really helps me make precision cross cuts that are easily repeatable and safe.

table saw flying dutchman

The riving knife which you see behind the spinning blade keeps wood that has tension in it from hitting the rear of the spinning blade, which at the rear is pulling up thus causing kickback.

maloof notch table saw

Here i'm cutting out the notches in the rear corners of the seat, i'm using a miter gauge with a large fence and some clamps to hold the seat while I make the cut.

band saw seat maloof notch

The front notches get most of the material removed on the band saw, I trim to about 1/16'' of the final notch size, then clean the joints up using a jig and a router.

walnut bar stool seat blanks

Here are 4 beautiful walnut seat blanks

front maloof notch router jig

I now clamp my front joint jig the the seat and clean the joint to its final size using a router with a bushing that rides along the jig.

bar stool seat blanks

Now we are well on our way , the notches have been cut for all of the legs.

bar stool seat blanks

The notches then have a rabbit on the top and bottom of the joint to create a tongue which will fit into a dado groove in the legs, this is call a Maloof joint.

sculpting seat kutzall carbide

Starting to sculpt the seat using my Kutzall carbide grinding wheel

maloof style seat bar stool

Cherry seat has been sculpted and sanded to 500 grit, some more shaping still need to be done at the front of the seat.

bar stool seat carving

The seat above has not been carved yet, you can see the depth holes which help me carve to the depth that I want.

sanded maloof style bar stool seat

Pair of cherry seat blanks

bar stool seats legs

4 seats and rear legs

cherry walnut legs

Nice legs!

maloof joint birdseye maple

This is a seat that has birds maple being used as the internal blank which is the exact thickness of the tongue I created, the dado in the leg is then cut to fit the tongue.

round over shaper table maloof

3/4'' round over on the shaper table

shoulder plane dado

The dados get cleaned up with a shoulder plane to fit

vintage hand plane verities

The old fashion way (-:

a chair is born rough

Look a chair is born!

maloof style bar stool parts

I forgot the glue, kidding just a pile of legs and a seat for a Cherry bar stool

bar stool line up

Line up of 9 sculpted bar stools well on there way through the fabrication process

maloof seat round over router table

Initial shaping on the seat

remove leg waste

Always nice to loose a few pounds off your legs

raised router bit

5/8'' round over used for initial shaping on the legs

rounded over walnut cherry legs

Now you can see the form staring to take shape

bar stool front leg glue

Finally gluing the front legs onto the first walnut seat

paul lemiski grind kutzall maloof seat bar stool

I've had my morning coffee and ready to grind!

birds eye maple bar stool seat

After the first session of shaping using my angle grinder and kutzall carbide grinding wheels by Oliver.

glue birdseye maple walnut seat

More legs more clamps

9 bar stools

I've been busy, all the legs have now been glued to the bar stool seats

kutzall grinding discs

These are my tools course and medium grinding carbide grinding wheels by kutzall, I love these things very safe never catches and lasts forever!

cherry walnut bar stool stringer glue up

Clamping up some leg stretchers, still lots of work to do but i'm well on the way to making some beautiful and comfortable bar stools.