Windsor Chair Online Assembly Instructions Date: 1/4/2007
Other Chairs Offered Philadelphia Arm Chair New England Comb Back Sackback d Arm Chair 13 Inch Tri Legged Stool 15 Inch Tri Legged Stool Bow Back Side Chair Fan Back Side Chair 44 inch Comb and Knuckle Settee 44 Inch Double Oval Bowback Settee Page 1
Table of Contents About Us 1 Table of Contents 2 Parts and Tools needed 3 Base Assembly 4&5 Wedging and Shaping of Seat 6 Grinding and sanding the seat 7 Leveling the chair 8 Installing Spindles and Arm 9 Installing the Back Bow 10 Wedging The Arm and Bow 11&12 Installing a side chair bow 13 Installing a comb back 14 Assembling a Settee 15 Basing up a Settee 16 Wedging and sanding a Settee 17 Leveling a Settee 18 Installing an arm on a Settee 19 Installing a bow on a Settee 20 Page 2
Tools Needed Rubber mallet Metal Hammer 2 Foot Level Set of Drill Bits Set of Wood Chisels Good Quality Yellow Wood Glue Sander (Orbital) Sand Paper (40 grit Thru 180 grit) Dovetail or Coping Saw Page 3
Basing Up Start by dry fitting the base stretcher system together. Insure that you have a narrow end and also a wide end as shown in the photo. If they are even turn one of the side stretchers around. Remember which way you took apart the last stretchers. Glue the inside of the holes (A broken pencil or small dowel dipped in wood glue and spun in a circular motion inside the stretcher hole will ensure enough glue) Use a rubber mallet to drive the side stretchers onto the center one. Place the Stretcher system down on a flat bench. Rock the system back and forth ensuring that both side stretchers are touching the bench at the same time. Page 4
Basing up Next, prepare the seat for assembly. The bottom of the seat needs to be sanded.( I prefer hand planeing the bottom for authenticity). The edges also need to be sanded. Hand sanding or an orbital sander will work if you don t have a bagging sander. (shown) Time to glue the base together. Be sure to have the base parts ready before you begin. Glue the leg holes first, then glue the large seat holes. (Bottom of seat facing up) Slide legs into already glued Seat. (Only insert legs half way into seat hole. Leave them loose in the holes to allow for stretcher installation.) Now install the stretcher assembly into the leg holes. Be sure the wider openings between the two side stretchers are toward the front of the chair. The process of gluing the base together should only take a couple of minutes (remember the glue is drying) Page 5
Basing Up and Wedging the seat Use the rubber mallet to drive the legs onto the stretcher assembly. (Do this to all four legs, flipping the base as you drive the legs onto the stretchers). Flip the chair upside down so the seat rests on a couple of thick pieces if wood. This insures the legs that are now sticking though the top of the seat do not touch the bench. Using the hammer, drive the legs into the seat until the shoulder of the leg bottoms out, or cannot be driven further. Do this firmly but be careful not to drive the legs too deep. (this could split the seat). Remember, the glue is drying the entire base assembly should be completed in 3 to 5 minutes. Right the chair, and place onto the floor. Take the 7/8 Wide wedges that are supplied with your kit. Dip them in glue one at a time. With the hammer, drive the wedges into the pre split legs. (Complete each leg before you glue the next wedge). Page 6
Wedging, Grinding and Sanding the seat After the wedge is driven in as far as possible with the hammer, use the side of a chisel to drive the wedge down into the leg until it drives no farther. (When the wedge stops don t force it). Cut off what's left of the leg and wedge as close to the seat as possible. Make sure the legs and stretchers have not shifted. Let the base dry thoroughly. (If they have moved use wood clamps to hold them until dry). Next, finish grind and sand the scalloped part of the seat. Take your time, remembering the legs sticking though the top are a much harder wood. Work them down first. Finish sand by hand or with a orbital sander Page 7
Leveling The Chair Start by finding a level area on a bench or table saw top. Using a two foot level is easiest. Level the seat in one direction: across the seat. Use the small wedges provided for the back spindles to level the base. Keep the level on the chair front to back and measure from the bench to the bottom of the level. The front of the seat height should be 17 from the floor after the legs are trimmed. The back of the seat should be 16 1/2 from the floor, to allow the chair to lay back. After the legs are marked you will need to cut them off. A band saw works great for this but a hand saw will work well too. Sand the bottoms level to the line you marked. Next, determine how much leg needs to be removed from the front legs to get the front of the seat height to 17. Use a pencil laying flat on a chunk of wood of the proper thickness to mark the cut on the front legs. For example, if the front of the seat was 17 3/4 leveled with the wedges under it and the pencil lead is an 1/8 off of the block of wood, you would need a block of wood 5/8 thick. Remember to take a 1/2 more off of the back legs. Page 8
Installing an Arm on an Arm Chair Then, measure from the middle back of the seat to the bottom of the arm in the very center of the arm. Insure that it is 8 3/4 from the back flat part of the seat to the bottom of the arm, as shown in this picture. (The only exception to this is the Philadelphia Arm as it lays the same height of the arm post.) Finish sand and do any shaping and carving on the arm before you begin. Next, dry fit all your spindles and arm posts so you know where they go when you are gluing up. Glue the arm post holes. Insert your arm posts, and set them with your hammer. Then flip the chair over and wedge them. Glue and insert all the spindles. Slide the arm down over the spindles, lining the spindles into the proper holes on the way down. Before you slide the arm down on the arm posts, glue the arm post holes and the short spindle holes. Now that the arm is in position, peg it to keep it in place. Use the 3/16 drill bit and drill thru the arm and center spindle all the way though the back of the arm. Using one of the supplied dowels dip it in glue and slide it though the arm and leave it to dry wile you work on the rest of the arm. Page 9
Installing an Arm & Bow on an Arm Chair Next, wedge the arm posts and shorter spindles. Take a sharp chisel and hammer place the chisel blade on the end of the arm post perpendicular to the grain of the wood on the arm. Use the hammer to drive the chisel into the post and split the top of each post. Split both post and what ever short spindles you have. Use the 1/2 wedges for the arm post and the 3/8 for the spindles. Dip them in glue and drive them into the split you have made on the post and spindles. ( Insure that when you Split the arm post from the top and the bottom that you are perpendicular to the grain of the wood in the seat and the arm. If you drive the wedge with the grain there is a fear of splitting.) Now, prepare the bow for installation. Sand the bow by hand to remove the burs that have accrued during the drilling process. Glue the holes in the bow. Starting with the outside spindles first, install the bow. The outside spindles will be the first to start into their holes and then the second ones in. On the third spindles in, start sliding the bottom of the bow into the arm rail hole. (Do this one side at a time. This sometime can be a quite difficult step every steamed and bent piece of wood is different. It could be bit of a strain to squeeze the bow into the holes on the arm rail) Page 10
Installing, Pegging, and Wedging the Bow Once the bow is on you need to make sure it is at the proper height. It should be 22 1/2 off of the back, flat part of the seat. Do this by knocking the bow down with the rubber hammer. Also measure along the second spindle in on each side to check that they are equal. Adjust if necessary. Drill though the arm rail and through the end of the bow with a 3/16 drill bit. Do this on both sides of the chair. Dip one of the 3/16 dowels into wood glue and insert it into the holes just drilled, one at a time. Cut off the top of the spindles about 3/8 to 1/2 above the bow. Page 11
Installing, Pegging, and Wedging the Bow Using a chisel that is wider than the spindles, split the spindles perpendicularly to the grain of the wood in the bow. Dip the end of the 3/8 wedge into some glue and drive the wedge into the splits just created until the wedges are seated in the bow. Allow adequate dry time. At this point, the chair should be complete and ready for the finishing touches. Trim off all of the pegs, wedged spindles, and arm posts. Sand all the tops of the spindles and anything else that needs sanding, either by hand, or with an orbital sander. Always remember: sanding is much easier to do before the assembly process has started. Page 12
Installing a Side Chair Bow Sand the bow inside and out: this is much easier done before beginning assembly. Insert all of the spindles into the bow before the bow is put on the chair. Glue both the bow and the spindle holes on seat. Slide the bow into the outer holes of the chair seat. (As shown in the picture) Gently slide the spindles down to the top of the holes in the seat, so the spindles are just above the holes in the seat. Using a glue brush, glue the spindles just above the bow. Then, drive them down into the seat with a hammer until they bottom out in the seat. Page 13 Next, measure from the back flat area of the seat to the highest center point of the bow, 22 1/2. Cut the spindles off approximately 3/8 above the top of the bow. Split the spindles with a chisel perpendicularly to the wood grain of the bow. Now dip the 3/8 wedges in glue, one at a time, and drive them into the spindles. Let the spindles dry while completing Flip the chair upside down, and use a chisel to split the end of the bow underneath the seat. Make sure that to split the bow perpendicularly to the grain of the wood in the seat. Drive the 3/4 glued wedge into the end of the bow and use the side of a chisel to drive the wedge down until it is seated into the seat. Use a saw and cut what is left over flush to the bottom of the seat. Sand. Flip the chair back onto its legs and cut the spindles flush to the top of the bow. Finish Sand.
Installing a Comb Back The comb is cut out, carved, and drilled before it is packaged. Sand the inside, backside, and top of the comb rounding the top cut edge. Sand thoroughly. Glue and install the side post first, then flip the chair over and wedge the side post perpendicular to the wood grain in the seat. Right the chair and glue the spindles into the seat. (On a comb back arm chair this has already been done). Flip the comb upside down and glue the holes. Slide the comb onto either one of the end spindles or side posts. Feed one spindle at a time until you have all of them in their proper hole. Use the rubber hammer to seat the fan down onto the spindles. Measure from the seat to the bottom of the comb 18 1/2. Drill with 3/16 bit though the comb and center spindle, all the way though. Glue and insert a dowel. Repeat this on the outside post or spindles. After they dry, trim and finish sand. The height from the seat to the bottom of the comb. New England: 24 1/2 Philadelphia: 28 3/8 Page 14
Assembling a settee Start by collecting the three side stretchers and two center ones. Take one of the side stretchers and one center stretchers. Glue the hole on the side stretcher and insert the center stretcher. Use the rubber mallet to seat the center stretcher into the side one. Do this to both of the side stretchers. The stretcher with the hole all the way though is for the center legs. While your stretchers are drying, start the work needed on the seat. Sand the edges smooth by hand or a orbital sander if you don t have a bagging sander (shown). Sand or hand plane the bottom of the seat. ( It is much easier to pre-sand any of the parts before assembly. Flip the chair upside down so the seat rests on a couple of thick pieces if wood. This insures when the legs a put into the seat the legs do not touch the bench. Glue the leg holes with plenty of wood glue. Glue the holes in the legs. Place the legs into the leg holes on the bottom of the seat. Do not slide them all the way in yet. This allow them to be spread open to insert the stretchers. Page 15
Basing up a settee Lay the side stretchers out on a bench with the preglued center stretchers touching one another. Notice how there is splay on the outer side stretchers. The front legs of the settee are set farther out than the back ones. Insert one pre-glued side stretcher into two end legs. Glue the hole on the remaining side stretcher and install it between the two center legs. At the same time insure that the center stretcher slides into one half of the stretcher just installed. Next, install the last pre-glued stretcher into the other side legs and also into the center side stretcher. At this time hammer the legs flush into the seat. Take the now assembled base and lay it on its side on the floor or bench. Using a rubber mallet drive the legs onto the side stretchers. Make sure all of the base joints are seated together. Page 16
Wedging and sanding a settee Flip the settee seat onto it legs and collect the 7/8 wide wedges. Dip a wedge into wood glue and insert it into the split in the leg. Using a hammer, drive the wedge flush to the top of the leg. Then use the side of a chisel to drive the wedge until it stops. Do not force the wedge it is deep enough when it stops. Repeat this on all the legs. Insure that the base has not spread apart and let it dry at least 20 minutes. Cut what is left of the legs and wedges as flush to the seat as possible. Next, finish grind and sand the scalloped part of the seat. Take your time, remembering the legs sticking though the top are a much harder wood. Work them down first. Finish Sand the seat and clean up any glue. Page 17
Leveling a settee Find a level bench or table saw top. Set the settee on the level surface. At this time, the settee will rock back and forth on the center legs. Use some of the wedges that are supplied with the kit to level the settee across its length. Measure from the table to the bottom of the level that is now laying across the seat front to back. After all the legs are marked. Use a hand saw to cut the legs off at the lines that you previously marked on the legs. Use some sand paper to clean up the bottom of the legs and knock the sharp edges off. Set the settee back onto the bench to insure it does not rock. Adjust if necessary. Next, determine how much leg needs to be removed from the front legs to get the front of the seat height to 171/2. Use a pencil laying flat on a chunk of wood of the proper thickness to mark the cut on the front legs. For example, if the front of the seat was 17 3/4 leveled with the wedges under it and the pencil lead is an 1/8 off of the block of wood, you would need a block of wood 5/8 thick. Remember to take a 1/2 more off of the back legs. Page 18
Installing an arm on a settee Prepare the arm for installation by sanding to remove any burs left from drilling. Slide the arm down on the spindles. Before the arm is lowered down onto the short spindles and arm posts, glue those holes. Split the top of the short spindles and the arm post perpendicular to the grain of the wood in the arm. Dip a 1/2 wedge in glue and drive it into the arm posts. Repeat this with the shorter spindles. Next glue the arm post holes and install the arm post insure that the already split arm post is put into the seat with the split perpendicular to the wood grain in the seat. Hammer them flush into the seat. Flip the settee base over and wedge the arm post then cut them off flush to the bottom of the seat. Sand and clean up any glue. Next glue all spindle holes and install the spindles the four short spindles going toward the front. Use a hammer to seat the spindles. Measure from the center back of the seat to the bottom of the arm on the center spindle. Insure that it is 8 3/4 from the seat to the bottom of the arm. Use a 3/16 drill bit and drill though arm and center spindle. Use one of the supplied dowels glue and insert into the arm. Cut the top of the arm post and spindles flush to the top of the arm and sand. If you would like to carve the edge of the hand on the this is the time to do it. Page 19
Installing a bow on a settee Sand the bow before assembly to remove any burs from drilling and flatten the raised grain from the steaming process. Glue the holes. Slide the bow down over the outer most spindles first then the second ones in from the outside. At the same time, insert the bow into the arm. Measure the bow from the center of the seat to the bow, 22 1/2. Also measure at the second spindle in from the outside and insure both are equal. Drill though the arm and end of the bow and insert the 3/16 dowel to hold it in place. Cut off flush with bottom of arm Use a saw and cut the remaining spindles off 3/8 to a 1/2 above the bow. Using a chisel split the spindles perpendicular to the grain in the wood of the bow. Using the remaining 3/8 wedges dipped in glue, drive the wedges in one at a time. Cut the remaining spindle off flush with the bow, and finish sand. Do a final inspection clean up glue and sand where necessary. Page 20
About Windsor Chair Online Windsor Chair Online was started in Ohio in 2006 by Master Craftsman, Chris Benner. Chris began his career by training with one of the foremost cabinet and furniture makers in the country. He has specialized in building fine antique reproduction furniture since 1991. Chris recognized a need in the market for high quality Windsor chair kits that were designed specifically for recreational or professional woodworkers. Chris lives in a Colonial style home, in historic Lebanon, Ohio. He enjoys spending his free time with his wife and son, and his faithful dog, Jake. We invite you to join the woodworkers of the past, and explore the remarkable world of Windsor chair building. Our instruction manual can always be improved. Your questions and comments are always welcome please email any comments to Chris@windsorchaironline.com 432 East Mulberry Street Lebanon, Ohio 45036 Phone: 513-934-0292 Fax: 513-934-0292 Email: info@windsorchaironline.com