Rob Hare attended my woodworking club meeting this evening and showed,
through photos and explanation, how he made coopered and iron chairs as
shown at http://www.robhare-furnituremaker.com/Chairs/chairs.html
Step one... start with a $5K slab of rough cut claro walnut...
Flatten the surface with a hand planer.
Cut to rough shape.
Rip and resaw so that book matched arm stock is roughed out.
Cooper the arms and glue up with West System epoxy.
Smooth the outside curve.
Gauge the thickness and then thickness and smooth the inside curve.
The back goes through the same process.
Move on to the forged metal work and leather upholstery.
At the end of the process you have a very nice chair!
There are no gaps in the joinery... the epoxy is to insure it stays
together. I have other associates who sell into the gallery, museum and
international collectors market and if there is a theme it's that they make
sure their stuff doesn't fail.
Rob informed us that the first sale of this style was for a pair of
chairs... he scales them to the purchaser.
The one he brought with him was the first one. I estimate it weighed in
excess of 200 lbs... and wouldn't be surprised if it were 300.
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