Three-Legged StoolComments (0)
Custom jigs ensure fool-proof production
Make the seat
Begin by making two seat templates from 1/2" plywood or MDF, referring to the pattern shown. In the mortising template, drill small awl access holes at each mortise center point. Then make the seat blank from 5 / 4 stock. When making multiples, I dress a pair of 8 × 30" boards to 1-1/8" thick, with each length providing one half of two seats. After edge-gluing the boards together for a good grain match, rip the lengths to 14" wide, keeping the joint centered. Then crosscut each blank to 14" long. For each blank, mark the center point on both faces, and drill a 3/8"-dia. hole 1/4" deep into what will be the underside to create a pivot point for jig location. Bandsaw the blank round as shown.
Place the mortising template on the top side of the blank with its center line aligned with the blank’s grain direction. Then poke an awl through the template holes to locate the leg mortises on the blank. Using a drill press ramp as shown, bore a 1"-dia. hole at each location. Next, dish the seat using the jig shown, before moving back to the bandsaw to cut the final triangular profile that you’ve laid out on the underside of the blank using the shaping template. Afterward, sand the edges to remove any irregularities, and then round over the underside using a 3/4" roundover bit and the top side using a spokeshave. Finish up by plugging the center hole and sanding the bottom through 220 grit. Leave the top at 120 grit for now.
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