Hank Chair

Jory Brigham

Designed as a static lounge chair, the Hank Chair's sophistication lies in the details. The Hank appears in many of Jory Brigham Designs collections because of its versatility and variety of cushion options. This course will cover the upholstered cushion version. With 24 different joints, the chair is sure to be an interesting build. Jory primarily uses the Festool Domino for his joints but Marc Spagnuolo will provide supplemental content showing how to make the same joints using a router and traditional loose (slip) mortise and tenon joinery.

Chair measures approximately 30"D x 28"H x 29"W

Save time and effort with our pre-made templates for this project.

  • 19 lessons
  • 258 min
  • $75.00
  • Hank Chair Template CNC File

    A vector file in DXF format for use on a CNC, downloadable upon purchase.

Here's what we'll cover:

  1. Introduction

    A little biographical background on Jory and the design of the Hank Chair.

  2. Templates

    A special guest stops by to show the template construction process and Jory tells you what to do with them.

  3. Side Components

    The legs and arm rests are cut to rough size and joinery surfaces are prepped.

  4. Side Assembly

    The two legs are glued to the arms.

  5. Side Assembly – Alternative Joinery

    A non-Domino option for the arm to leg joints.

  6. Side Shaping

    The side assemblies are cleaned up, flush trimmed, and the back of the arm is beveled.

  7. Back Rest

    The back rest blank is beveled at both ends.

  8. The Seat

    The seat frame is and shaped using the template.

  9. Seat – Alternative Joinery

    Joining the seat parts with loose mortise and tenons.

  10. Side to Back Joinery

    The arms are joined to the back rest.

  11. Side to Back – Alternative Joinery

    The arm joins the back rest with a router-cut mortise and tenon joint.

  12. Back Rest Curves

    The back rest receives a curve cut on both the front and rear face.

  13. Arm & Back Shaping

    The arm receives a tapered bevel and the back is beveled and sculpted.

  14. Leg Tapers

    Tapers are added to the legs to give a sleeker look.

  15. Upholstered Seat

    The seat is wrapped in gorgeous soft leather.

  16. Final Assembly

    The seat is joined to the sides and the whole chair is glued together.

  17. Final Assembly – Alternative Joinery

    Attaching the seat to the chair side assemblies with loose mortise and tenon joinery.

  18. Remaining Details

    The chair gets the final details.

  19. Finishing

    Jory applies a perfect oil finish to the Hank Chair.

What will I receive?

  • Detailed cut list and plans including a PDF (Metric and Imperial) and patterns so you can make your own templates.
  • Hours of detailed video instruction (19 videos in total) showing every step of the build.
  • All videos and plans are digital and will be available for download upon purchase. 

What will I learn?

  • Walnut grain selection
  • Using sleds for tricky cross-cuts
  • Bevels and miter cuts
  • Complex Domino joinery
  • Alternative loose tenon construction (supplemental content from Marc)
  • Clever glueup strategies
  • Power carving curves
  • Basic seat upholstery

What will I need?

  • Lumber estimate: 16 BF of 8/4 hardwood, 5 BF 6/4 hardwood, 4 BF 12/4 stock. Bell Forest Lumber Kits available here (Guild members get 10% off with code).

  • Planer/Jointer (alternatives: purchase pre-milled lumber or use hand planes)
  • Tablesaw with a Miter Gauge and/or sleds
  • Bandsaw with at least 8″ resaw capacity
  • Router
  • 1/4 Roundover Bit
  • Shallow Pattern Bit
  • Top Bearing Pattern Bit for flush trimming
  • Miter Saw
  • Random Orbit Sander
  • Circular Saw or Track Saw
  • Angle grinder with carving tool
  • Power planer (the hand-held kind) or a classic hand plane for tapering the legs

Reviews:

Super fun build. I had Staples print the patterns $4.23 well spent. The videos and plans together made the project very straight forward. I had no significant questions that were not readily answered by the lessons. The technique of cutting calls into the excess wood was genius. I doubt I would ever have thought to do that and it made the joinery very rewarding.

Rodney Hiltbrand
Guild Member

Awesome project! I love that Jory has a distinct style both in the project design as well as his in shop techniques. A valuable addition to the Guild pantheon. Can’t wait to get started on a few chairs.

btschmid
Guild Member

Such an excellent project. Jory has a very interesting and unique method of getting things done. I’ve definitely learned a ton in this project and picked up tips and tricks that i’ll be using in the future. And oh…The chairs are beautiful too !

Alec McMahon
Guild Member
Read all reviews / Leave a review

About Your Instructor:

Jory Brigham is a California-born artist, designer and builder with a passion for creating lasting works by hand. Growing up among generations of woodworkers and craftsmen, Jory discovered his own creative voice within the family trade at an early age. Though his artistic inspiration pulls from decades throughout the twentieth century, many of Jory’s designs play with colors and textures to pair unique perspectives with classic, mid-century balance.

Jory now creates in his dream shop located in Paso Robles, California, where he pulls inspiration from the beautiful landscape that surrounds him. He loves sharing his knowledge and space while teaching workshops for woodworking and furniture design, along with running his primary furniture business. His main motivation is to show his two children the value of hard work and passion for their chosen career path, while constantly growing personally and pushing the limits as an artist.