This is an Advanced Project!
Advanced does not necessarily mean DIFFICULT. It simply means that there won’t be quite as much hand-holding as we normally feature in Guild projects. You may have to construct a couple of shop-made fixtures/jigs to get some of the tasks done but if you’re interested in a project of this caliber, that shouldn’t be a deal-breaker.
What will I receive?
- Detailed cut list and plans including a PDF and a SketchUp file (Metric and Imperial).
- Hours of detailed video instruction (14 videos in total) showing every step of the Morley Bar Stool build.
- All videos and plans are digital and will be available for download upon purchase.
What will I learn?
- Slip tenon joinery
- Mortise and tenon joinery (Integral)
- Cutting accurate double-slip tenons using spacers
- How to cut mortises efficiently and accurately with plunge router
- Using spoke shave, hand planes to shape parts
- Using templates and jigs for pattern routing to produce accurate and efficient parts
- Use an “L” fence effectively
- Importance of reference faces
- Cutting brass and inlaying into wood
- Cutting and Shaping Curved Seat and Curved Crest Rail
- Pinning with brass dowels
- Conversion varnish finishing tips
What will I need?
General Tools for building the Morley Bar Stool:
Table Saw, Bandsaw, Jointer, Planer, Drill Press, Drill, Random Orbit Sander, Plunge Router, Router Table
- 18 BF 8/4 Hardwood
- 3 BF 4/4 Hardwood
- Wood Kits can be purchased here.
- If you’d like a simple kit that contains all the brass you’d need, head to Southern Specialty Supplies. As a Guild member, you’ll receive a code for an additional 10% off your purchase.
- Below, I’ve included links to the parts from other sources, though it will cost more than the kit.
- McMaster-Carr 8953K149 Ultra-Machinable 360 Brass Rods, 3/8″ diameter, 1 Foot Long (5 per stool or purchase longer and cut to size)
- McMaster-Carr 9124K58 385 Brass 90 Degree Angle, 1/8″ Wall Thickness, 2″ x 2″ Outside, 1 Foot Long (5 per stool or purchase longer and cut to size)
- 1/8″ Brass Rods (These are optional and Philip uses two small pieces to pin the brass to the foot rest so you don’t need much. Shop around.)
- Top and bottom bearing flush trim bit
- 1/2″ Straight Bit (for mortises)
- 1/4” Radius Roundover Bit
- 3/8” brad point drill bit for brass rods
- 3/8” upcut spiral bit
- Non-ferrous 10” table saw blade
- ½” guide bushing for router
Stuff I use that you might find useful:
- Pre-Made L-Fence
- Contour Sanding Pads
- MatchFit Clamps
- Smoothing Plane
- Flat Spokeshave
- Good sanding blocks (duroblocks, prepping weapon)
- 3/8 – 1/2″ Chisel
- Gray scotch brite
- I recommend a ¾” 3 tpi bandsaw blade
- Figure 8 Fasteners (also known as table top hold downs)
- Titebond Original
- Purchase a CNC File here.