YIKES! Those feet belong to Ray Sykes!
As you can see; the welding is quite handsome!
(this does not take into account the arms)
There are 10 different size pieces total. (11 total parts per chair)
9 are single pieces (no other piece is the same)
1 is a double (two pieces are identical)
The identical pieces run vertically and are the parts to which the frame is screwed during final assembly.
The pictures will show how they are to fit together and that ought to answer some questions. I have glued mine together before stapling them, it might not be a bad idea to do so. (might be overkill but at this point we only have ONE Heavy Wire staple gun for assembly)
The measurements given in this description are correct. Some of the pictures show measurements which have been revised. Please use these measurements. At this point we anticipate doing 220 of these chairs. (There are also 30 other chairs which will be reupholstered AS IS and will not require new wood parts)
There are two parts which are made from 7/16″ OSB
SEAT is 18½” x 18½” (you can get 10 from a 4×8 sheet)
BACK is 15⅞” x 20⅝” (you can get 12 from a 4×8 sheet)
There is one part which is ¼” Luan
OB is 15⅞” x 20⅝” (you can get 12 from a 4×8 sheet, same as BACK)
There are four parts which are ¾” pine. I bought furring strips because the edges were slightly rounded.
SEAT BACK STRIP is ¾” x ¾” x 18½”
SEAT FRONT STRIP is ¾” x 3½” x 18½”
IB TOP RAIL is ¾” x 2″ x 20⅝”
IB BOTTOM FILLER is ¾” x 1″ x 18″ (* see footnote)
VERTICAL IB CLEATS ¾” x 1½” x 12⅛” (only part where you cut TWO per chair! )
There is one part cut from 5/4” pine. This is likely to be 5/4” Pressure Treated but the PT is not required for the job… it’s just the cheapest way to get 5/4” lumber
THIS PART COULD BE 1” plywood if that is cheaper. It is strictly a filler that must equal the thickness of the metal back frame (finishing one inch thick)
IB TOP FILLER (TOP BRACE) 5/4” x 2⅝” x 18
* The IB FILLER will be set on edge. It should equal the thickness of 5/4” stock. (i.e. Use a piece of the 5/4” to set the rip-fence)
The Outside Back is attached by brad gun
(we currently have only one brad gun and
one heavy wire staple gun for construction)
shows how the TOP BRACE (IB TOP FILLER) is installed
This is a new part for our department.
take a close look and you will see the screws. This will all be hidden by the outside back.
this is cut from 3/4″ stock but is ripped to be the same thickness as the 5/4″ stock. It is attached ON EDGE!
showing where the rounded edge should be placed
how the seat, covers the welded seat rail
initial idea for tight fit of parts