By Stevie Henderson
A suite of domestic and backyard furnishings tasks, which name just for using low-cost, regular 2" X 4" lumber, universal instruments and easy options. The designs variety from conventional to modern.
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Additional info for 2X4 Furniture: Simple, Inexpensive and Great-Looking Projects You Can Make
Cutting the Mortises All the chair parts except for the vertical slats are connected with 1⁄2-in. Years ago, I developed a simple jig to cut the mortises for a batch of screen doors, and I was able to use it again for this project. This jig is made of 3⁄4-in. plywood with sides that act as a carriage for the router. A 5⁄ 8-in. slot runs down the middle of the jig, stopping 2 in. from each end. Two adjustable stop blocks sit square in the carriage and control the length of the mortise. Straight tenons cut before sawn curves I held the piece to be mortised in the jig by clamping it to the underside, below the 5⁄ 8-in.
Straight tenons cut before sawn curves I held the piece to be mortised in the jig by clamping it to the underside, below the 5⁄ 8-in. slot. I used my 3-hp router with a 1⁄ 2-in. by 4-in. solid carbide up-cut spiral bit, adjusting the depth of cut with stops on the router. Even with the jig, this was a timeconsuming process. Router bits don’t cut square-cornered mortises. Rather than cleaning out all the corners by hand, I devised a method that works really well. I chucked a Lie-Nielsen® corner chisel into my drill press (make sure it’s unplugged).
Because both tenons are cut without repositioning the part, they come out perfectly in line even if there is some twist or unfairness in the curve. The jig also guarantees that all the parts will have the same shoulder- to-shoulder dimension even if the overall lengths of the raw parts vary slightly. Of course, a lot more can be said about cutting accurate joints on curved parts, but hopefully, these techniques will get you around the next bend. BRIAN BOGGS is a chair maker in Berea, Kentucky, and teaches seminars on ladderback chair making.
2X4 Furniture: Simple, Inexpensive and Great-Looking Projects You Can Make by Stevie Henderson