Shaping the Seat James Mursell Introduces Us to the Processes Involved in Making One of His Windsor Chairs

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Shaping the Seat James Mursell Introduces Us to the Processes Involved in Making One of His Windsor Chairs Deconstructing Windsor chairs shaping the seat James Mursell introduces us to the processes involved in making one of his Windsor chairs he seat is the foundation upon which all Windsor chairs are Tbuilt. In fact it is the solid wooden seat that defines the term ‘Windsor’. In this context ‘Windsor’ describes a form of construction, rather than a style, where most of the components below the seat are socketed into it from below and most of those above are socketed in from above. In addition, no components pass from one side of the seat in to the other. Within the constraints of this definition many things can be made – chairs, stools, tables and cradles. There is plenty of scope for the imaginative woodworker to solve many ‘problems’ using this form of construction and to develop new styles that may become iconic in years to come. Chairs are always said to be one of the most complicated tasks for cabinetmakers, but the Windsor technique is deceptively simple and highly efficient in making a light structure that will support at least 10 times its own weight. Windsor chairs are fine examples of synergy – where the whole is greater than the sum of its individual parts – and it always amazes me that a modest collection of components can make such a significant chair when put together. The secret of its success is that each component – other than the seat – is supported by so many others. PHOTOGRAPHS BY JAMES MURSELL Katie Walker’s Windsor rocker PHOTOGRAPH BY KATIE WALKER 24 F&C202 www.woodworkersinstitute.com PROJECTS & TECHNIQUES Deconstructing Windsor chairs In detail Back rail is steam-bent and keeps its square section The ends of the back rail are tapered to fit into the arm rail Arm rail is steam-bent and dowelled into the front arm support The back spindles run from the seat through the arm rail and into Front arm support is the back rail steam-bent The through holes for the legs and back spindles are angled Legs are through- Flat sections are left tenoned and around the perimeter of wedged into the the seat to make drilling seat for the connecting parts easier The seat is shaped to accommodate two people Front stretcher is steam-bent Front stretchers are through dowelled and wedged into the front stretcher ➤ www.woodworkersinstitute.com F&C202 25 ➤ The shape of the seat The seat is formed from a solid plank be comfortable, provided the edge is of wood and the thickness can vary rounded slightly as well. from 35-50mm. It can be difficult to A chair seat will be larger than a find sufficiently wide boards so two or stool’s because of the need to socket more may need to be joined. A simple in bows, spindles, stiles, arm posts, butt joint is the only sensible option slats and splats. It will also spread as dowels and biscuits are likely to further forward than the stool so that be exposed when hollowing the wood weight can be supported on the thighs for comfort. Great care should be as well as the bottom. In addition to taken to produce matching surfaces this, the presence of a back will make as the joint is likely to be subjected to it more comfortable than a stool, not considerable forces when the chair is just because the back muscles can in use. My preferred adhesive for this relax, but also because some of the is Titebond Original. sitter’s weight is taken on the back The top surface of the seat needs of the chair. Some chairs, particularly to follow the shape of the sitter’s rocking chairs, are very laid back and bottom if it is to be comfortable. We their comfort comes mostly from the have all sat on flat benches and within reduction of weight that is supported a few minutes begun to shift position by the seat. in order to help the blood to keep In plan view, seats can come in all flowing in the flesh between our seat shapes and sizes depending on the bones – ischial tuberosities – and the chair’s purpose, but the back profile seat. Our weight is concentrated in is likely to be rounded to fit the shape this small area when the seat is flat, of the bottom and the front is likely so the purpose of shaping a seat is to be wider to accept the naturally to spread the load over as large an splayed legs of the sitter. The size of area as possible so that numbness is chair seats is quite tightly constrained avoided. by the range of size of human beings. Cheap machine-made Windsors The width is likely to range from pay scant attention to comfort. They 380mm for a small side chair to may be inexpensive and they will around 610mm for a large armchair. support your body at a convenient The depth will range from about 380- height, but they will never be 485mm. comfortable as there is so little If you wish to design a new seat hollowing of the seat. shape, why not begin by sitting on The simplest Windsor seat is a board and drawing around your the round stool. The top may be bottom and thighs? If this shape is just 305mm in diameter, but if it is incorporated in your design it is likely hollowed by as little as 12mm it will to be comfortable. Drawing around the bottom and thighs to get measurements for the seat 26 F&C202 www.woodworkersinstitute.com PROJECTS & TECHNIQUES Deconstructing Windsor chairs Shaping the seat An adzed settee and my new favourite, sweet chestnut used radially to ensure a good profile. (Castanea sativa) can be quickly The slope at the back of the seat will shaped with the adze. A recently be steeper than at the front as the seat completed settee took just 20 minutes bones tend to be placed closer to the to adze and it was not worth the back than the front. As one moves from effort to dress up with ear defenders, the back, around the side to the front respirator, face mask and gloves. the slope gradually decreases. This Roughing-out is probably the most produces a comfortable hollow which hazardous of all the jobs in making prevents the bottom sliding forwards. a Windsor chair. Whether adze or Arbortech and adze Although my interest is limited to Arbortech-type tool, there is a risk of The travisher shaping seats by hand-guided tools, a fast moving blade making contact Once the hollow area is roughed out the production workshop is likely to with your body. Simple but effective it is the turn of the travisher. This and employ sophisticated techniques techniques must be adopted to the remaining shaping is my favourite such as CNC routing, or one or more minimise the risk. part of making a Windsor chair. pantograph-mounted routers which When using an angle grinder-based The travisher should first be used are guided by a scribe over a model tool I hold it firmly with both hands to smooth out the adze/Arbortech seat. Once set up, these techniques directly in front of my body with the marks and then to achieve the desired will greatly speed up the process and back pressed into my midriff and profile. The travisher, which is a the result will be identical every time. my elbows locked against my sides. curved spokeshave, is capable of both The division between jigged and Movement of the blade is via the aggressive and fine cuts without the hand-guided shaping is not the same wrists and the legs, which move my need to change the position of the as power tools versus hand tools. whole body from side-to-side. If my blade. The depth of cut is controlled The power of an Arbortech blade on elbows become disconnected from by adjusting the pressure on the an angle grinder makes it possible to my body I have much less control. blade while maintaining firm contact make larger mistakes more quickly between the nose of the tool – just than using an adze. Both require the Using an adze in front of the blade – and the seat. user to know exactly how he wishes to For the adze, my favoured position This is a knack that is easily mastered shape the wood and then be able to is to bend my knees and rest my and can be used with wooden achieve it by hand-eye co-ordination. forearms on the top of my thighs. spokeshaves also. While this contact is maintained it is Aesthetically, it is important to The Arbortech virtually impossible to hit my ankles, produce a crisp transition between The Industrial Arbortech is a fine tool. but loss of contact is dangerous. the back platform – insertion point for It takes just 12 minutes to rough out Before hollowing a seat I drill two the spindles – and the hollow area. every surface of a heavily-shaped depth holes where my seat bones Failure to do this may save a couple of elm Windsor seat. This represents a will be placed. Leave around 6mm of minutes work, but the seat will never significant saving in time and energy. wood at this deepest spot and all of be a classic. Similarly, transitions Elm (Ulmus procera) is particularly the hollowed area slopes down to the between the top, sides and bottom of tough to work, but softer woods such bottom of the holes. The adze cuts the seat should also be made sharp as tulipwood (Liriodendron tulipifera) towards the low point and needs to be and then softened with abrasives.
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