A fresh Oak log is first cut down into workable lengths to match various parts of the chair.  The pieces of log are then hand split down into billets .  This labor intensive process produces the long straight grain  which gives the spindles and bows their strength.

The chair is assembled using tapered socket tenon joints that are glued and wedged.  Using a bevel square  to set the angles, the joints are  hand drilled  with a brace and bit.  The bits are spoon bits which are  unique to chairmakers.  A reamer is used to ream the hole to match the tapered shoulder of the tenons.

The legs, stretchers, and arm stumps are made of maple.  They are  turned on a lathe by hand using turning gouges and chisels.

The seat is formed from a 2 inch thick  wide plank of Popular.  The plank  is hand planned to thickness and  then carved to form a deep comfortable saddle seat.   The tools pictured  to the left are a scrop, compass plane and  travisher. 

Seated at the  shaving horse using a drawknife and spokeshave a fresh split billet is whittled into a round spindle for the back of a Windsor.

 

  Storybook Joinery       Bench-Made  Reproduction Windsor Chairs & Period Furniture

                        "by hand, by eye, the 18th Century way"

Crafting A Windsor Chair

   The Chairmakers Tools

The final step is the distressed finish.  The chair is lightly sanded and a base color of "Milk" paint is applied.  A second color of paint is applied after the first coat has dried.   A portion  of the second paint coat is then removed to mimic wear and distress patterns like those found on originals.    Wear or distress patterns will l vary from chair to chair and no two  will be alike.  When satisfied with this process , the chair is branded and numbered.  The chair is then given no less than 3 coats of "Hand-rubbed" pure Tung oil to protect the finish.