Let’s Work on Those Limbs

Part 2 of the chair-building series.

When I make a chair, I typically rough out all the parts then focus on the chair’s limbs: the arms and the legs.

Let’s talk first about the legs. The legs for this chair are hexagonal – not octagonal. Why? Because I didn’t have any 8/4 mahogany. The thickest mahogany in my cellar is 1-5/8". If I use hexagonal legs, I can make legs that have the same volume as 1-3/4" octagons.

If my statement isn’t making sense to you, you can read a full explanation in the Stick Chair Journal No. 1. (Better hurry, we have only 909 in stock. That’s a joke. That’s a three-year supply.)

Hexagonal legs are cut from rectangular billets. A 1-5/8" x 1-7/8" hexagon has about the same volume of wood as a 1-3/4" x 1-3/4" octagon. Plus, hexagons have wider facets, which I like for this chair.

To make the hexagonal legs, rip (or rive out) the 1-5/8" x 1-7/8" x 20" pieces. The first step to hexagonalize them is to score a centerline on the end grain of one leg through the 1-5/8" thickness. Set your gauge to 13/16" an…