Rustic Chairs With Skye Gregson

MAJOR FUNDING FOR "THE WOODWRIGHT'S SHOP" IS PROVIDED BY... MORE THAN 40 MILLION PEOPLE WHO CARE FOR THEIR CARS AND HOMES CHOOSE STATE FARM FOR THEIR INSURANCE.

STATE FARM--A PROUD SUPPORTER OF "THE WOODWRIGHT'S SHOP."

CAPTIONING MADE POSSIBLE BY U.S. DEPARTMENT OF EDUCATION IF YOU HEAD UP INTO THE BEAUTIFUL ADIRONDACK MOUNTAINS OF NEW YORK, YOU'RE SURE TO FIND BEAUTIFUL MOUNTAINS, PRISTINE LAKES, BUT IF YOU'RE LUCKY ENOUGH TO GET UP INTO THE HILLS OVER SCHROON LAKE, NEW YORK, YOU JUST MIGHT ENCOUNTER A YOUNG LADY WORKING ON A SHAVING HORSE MAKING WONDERFUL RUSTIC FURNITURE.

HELLO, SKYE.

HI, ROY.

HOW ARE YOU DOING TODAY?

I'M DOING GREAT.

FOLKS, THIS IS SKYE GREGSON, AND SKYE, I LAST SAW YOU WHEN YOU WERE, I THINK, 12 YEARS OLD, BUT YOU'VE BEEN HELPING OUT WITH THE FAMILY MAKING RUSTIC FURNITURE SINCE WHEN?

WELL, SINCE ABOUT...

I WAS 9 YEARS OLD, AND MY FAMILY AND I HAVE BEEN WORKING ON DIFFERENT FACETS OF A RUSTIC CHAIR.

AH, THIS IS WONDERFUL.

RUSTIC FURNITURE HERE IN THE ADIRONDACK STYLE.

YOU TAKE THE STICKS AND THE NATURAL SHAPES OF THE FOREST AND MAKE THIS WONDERFUL, DURABLE, BUT STILL WHIMSICAL FURNITURE.

AND I SEE YOU'RE WORKING ON A PIECE RIGHT THERE.

WHAT'S THAT?

THAT'S RIGHT.

I'M TAKING A BLUNT, DULL BLADE, A DRAWKNIFE, AND WE'RE SHAVING OFF THE LAYERS OF THE BARK UNTIL WE GET TO THE HARD LAYER OF THE APPLE.

AND THIS IS AN APPLE RUNG THAT YOU'D SEE ON ONE OF THESE CHAIRS RIGHT HERE ACTUALLY.

AND THIS IS THE KIND OF CHAIR YOU'RE MAKING RIGHT NOW?

YOU KNOW, I'D LOVE TO SEE HOW YOU BUILD THIS WHOLE THING.

IS THAT SOMETHING WE COULD TAKE A LOOK AT?

CERTAINLY.

LET'S HEAD ON OVER TO THE SHOP.

I'LL GRAB THESE STICKS HERE, AND IF YOU'D GRAB THESE YELLOW BIRCH ROOTS, WE'LL TAKE THEM ON OVER.

GNARLY STUFF.

HERE WE GO.

WELL, HERE WE ARE AT THE SHOP.

OH, MY GOSH.

YOU GOT ENOUGH WOOD HERE FOR A MILLION CHAIRS.

OH, THIS IS GREAT.

THE LILAC PILES.

WE'VE GOT YELLOW BIRCH ROOTS, AND WE'VE GOT CHERRY BURLS.

WE'VE GOT UPRIGHTS IN THE CEILING.

WE'VE GOT ROCKERS.

WE'VE GOT IT ALL.

YOU'RE MORE THAN WELCOME TO PUT THAT THERE, IF YOU LIKE.

HOW LONG DOES THIS STUFF HAVE TO SEASON BEFORE YOU CAN USE IT?

WELL, WE LET IT DRY FOR ABOUT A YEAR OR 2.

SOME PIECES DRY FOR A LOT MORE, BUT WE GET TO THEM.

AND YOU KNOW EXACTLY WHAT'S IN HERE, DOWN IN THE BOTTOM OF THIS PILE?

OH, YEAH.

THAT'S RIGHT.

ABSOLUTELY.

ALL RIGHT.

WELL, HEY, SPEAKING OF SEASONED, HERE'S A SEASONED GENTLEMAN OF WOODCRAFT, BARRY GREGSON.

GREAT TO SEE YOU AGAIN.

GOOD TO SEE YOU.

IT'S BEEN ABOUT 10 YEARS AND I GUESS 10,000 CHAIRS ON YOUR PART.

NOW, YOU'VE GOT A BIG RUN OF CHAIRS HERE, TOO.

WHAT'S THIS HERE?

THIS IS A SIDE CHAIR.

WE'VE GOT TO MAKE ANOTHER 120.

WE LOST 120 OF THEM IN A FIRE UP IN LAKE PLACID IN A RESTAURANT.

SO WE'VE GOT TO DO IT AGAIN.

OH, MY GOSH.

BUT THIS IS THE KIND OF CHAIR YOU'RE GOING TO SHOW US HOW TO MAKE NOW?

IT WAS A SIDE CHAIR, THE DINING CHAIR THAT WE DO.

DAD DOES OTHER STYLES-- ROCKERS AND FANCY CHAIRS-- BUT THIS IS THE ONE I'M LEARNING RIGHT NOW.

WE START OFF HERE WITH THE BACK UPRIGHTS, AND WE LOOK FOR SOME FRONT UPRIGHTS TO GO WITH THEM, AND DO THE SIDES, BOTH THE SIDES, AND THEN WE DO THE BACK AND THEN THE FRONT.

OTHER ARTISTS MAY DO IT DIFFERENTLY.

THEY MAY START WITH THE BACK AND THE FRONT AND THEN PUT ON THE SIDES, BUT THIS IS HOW DAD SHOWED ME AND MY BROTHERS.

YEAH.

SIDE, SIDE, BACK, FRONT, SEAT.

YEAH.

ALL RIGHT.

AND I LOVE THE WOOD YOU'RE USING HERE.

YOU SAY ASH UPRIGHTS.

IS THAT RIGHT?

AND THEN APPLE HERE?

YEP.

ASH UPRIGHTS, AND THIS IS AN APPLE RUNG, AND WE BURNISH THAT DOWN UNTIL IT GETS TO A HARD CAVITY LAYER, AND IT GIVES US A LITTLE CATERPILLAR THERE.

WOW.

THAT'S WONDERFUL.

THIS IS RIGHT UNDER THE BARK THERE.

SO THAT BEAUTIFUL BROWN COLOR.

AND, BARRY, YOU AGE THAT OUTSIDE IN THE RAIN?

YES.

WE LET IT SIT FOR ABOUT 6 MONTHS WITH SNOW HITTING IT, RAIN HITTING IT, AND IT TANS THE BARK, AND IT TANS THAT CAMBIUM LAYER AND MAKES IT DARK LIKE THAT.

OH, IT'S BEAUTIFUL.

I'LL TELL YOU WHAT-- WALNUT SEATS.

OH, I LIKE THAT.

AND IT ALL MATCHES TOGETHER.

SO THE WHOLE BLEND OF WOODS HERE.

BUT I TELL YOU, WE'VE GOT TO TAKE THIS AWAY, BECAUSE I WOULD LIKE TO START WITH THE BARE BENCH AND LET YOU GUYS SHOW ME FROM THE GET-GO HOW YOU DO THIS.

YOU'VE GOT ALL YOUR WOOD GATHERED.

YOU'VE LET IT DRY.

HOW DO YOU BEGIN?

GOT SOME MAPLE OAK RIGHT THERE.

ALL RIGHT.

SO I GUESS THAT'S WHERE YOU START.

WE START WITH THE UPRIGHTS IN THE BACK, AND WE LOOK FOR A NICE BEND HERE, A LITTLE KICK-OUT.

SO THIS IS THE BACK OF THE CHAIR, AND I'M HERE AT THE FRONT.

ALL RIGHT.

AND THEN JUST...

THERE'S A POSSIBILITY.

DOES THAT WORK?

WELL, THAT DOESN'T LOOK LIKE IT HAS ANY KIND OF SWOOP OR KICK-BACK RIGHT THERE TO THAT.

UM, AN HOURGLASS SHAPE.

BUT, YEAH, IT'S NOT AS NICE.

OK. YOU'RE LOOKING FOR SOMETHING THERE.

ALL RIGHT.

I DON'T KNOW WHAT, BUT MAYBE I'LL KNOW IT WHEN WE SEE IT RIGHT.

YOU LOOK HERE AND SEE THAT STILL DOESN'T QUITE MATCH THERE, AND YOU GOT THE HOURGLASS SHAPE GOING, BUT THIS STILL DOESN'T HAVE ENOUGH KICK-OUT.

ALL RIGHT.

HOW ABOUT THIS ONE?

LET ME SEE, DAD.

SO YOU JUST KEEP BRINGING THEM IN-- THIS LOOKS NICE, BUT IT PROBABLY WOULD GO BETTER AT THIS HEIGHT.

HOWEVER, WE CAN CUT OFF THAT LITTLE HOOF DOWN THERE.

ALL RIGHT, AND I CAN SEE IT THERE.

THIS DOES HAVE A KIND OF SYMMETRY TO IT.

YES, AND A NICE HOURGLASS SHAPE HERE IN THE BACK.

THIS IS WHERE THE BACK IS GOING TO BE.

AND THAT'S WHY YOU NEED SO MANY PIECES OF WOOD-- SO YOU CAN DRAW FROM THIS INVENTORY... SIFT THROUGH A WHOLE SLEW OF THEM AND SEE WHAT WORKS.

SEE WHAT WORKS.

SEE WHAT WANTS TO PLAY TOGETHER.

ALL RIGHT.

RIGHT.

NOW WE'RE GOING TO LAY ONE OF THESE DOWN HERE.

AND WE'RE GOING TO TAKE A FRONT UPRIGHT HERE THAT WE'VE PUT ASIDE, AND WE LOOK TO MAKE SURE THE ARROW IS LIKE THIS.

SO YOU DECIDE WHAT THE ORIENTATION IS FRONT TO BACK NOW.

Barry: AND THEN HERE'S A SEAT RUNG I DID, AND I PUT THE NUMBER ONE WITH AN ARROW, SO I'LL PUT IT LIKE THAT.

NOW WAIT A MINUTE.

NOW, THIS ONE HAS A TENON ON IT.

THIS HAS BEEN TRIMMED DOWN.

CAN WE SEE HOW YOU DO THAT BEFORE WE GO ON ANY FURTHER?

Skye: YEAH.

LET'S TAKE A LOOK AT THAT.

WHAT HAVE YOU GOT HERE?

OH.

ALL RIGHT.

HERE, UM...IS A, UM... TENON CUTTER THAT WE USE, AND THIS HAS GOT A METAL HOLE IN HERE, AND WE GOT 2 SIDES TO SHAVE IT DOWN.

WE TRY TO AIM GOING CENTER DOWN ON THERE SO IT GETS A NICE LITTLE SHOULDER ON THERE.

ALL RIGHT.

SO IT'S LIKE A PENCIL SHARPENER KIND OF THING THERE.

YEAH.

WITH 2 BLADES.

THAT'S RIGHT.

AND WE'LL SHAVE THIS DOWN.

CRANK IT DOWN THERE WITH THE BRACE?

YEP.

UH-HUH.

PEELING IT RIGHT AROUND.

NOW, THIS IS ONE YOU CAN BUY, I GUESS.

PEOPLE ARE MAKING THESE NOW.

BUT I KNOW YOU GUYS HAD THIS MADE BY A MACHINIST FOR YOU.

SO YOU MAKE THEM YOURSELF.

IS THIS A WOODEN ONE?

THIS IS A WOODEN ONE THAT DAD MADE QUITE SOME YEARS AGO, AND HE PUT HIS OWN METAL PLATE ON THERE, AND THAT'S ANOTHER TYPE OF PENCIL SHARPENER TYPE DEAL.

SKYE, YOU MUST HAVE BEEN DOING THIS WHEN YOU WERE VERY LITTLE.

DO YOU REMEMBER DOING THIS AS A LITTLE GIRL?

YEP, I REMEMBER DOING THIS, AND MY BROTHERS AS WELL.

WE WERE ALL DOWN HERE-- DAD'S LITTLE ELVES.

IN HIS WORKSHOP MAKING CHAIRS.

THAT'S RIGHT.

THAT'S GREAT.

ALL RIGHT.

SO THAT'S THE TENONS, AND THIS WILL CUT, I GUESS, A LITTLE BIT BIGGER ONE, BUT YOU HAVE TO BE VERY PRECISE, I IMAGINE, IN THE SIZE OF THESE THINGS.

THAT'S RIGHT.

WE WANT IT STRAIGHT SO WHEN WE PUT THEM THROUGH THE UPRIGHTS THAT IT DOESN'T BUST THEM OUT.

AH, THAT WOULD BE BAD.

YEAH, THAT WOULD BE BAD.

BUST THEM OUT WOULD BE BAD.

ALL RIGHT.

SO HERE WE GO.

WE HAVE GOT AN UPRIGHT BACK, AN UPRIGHT FRONT, AND NOW YOU'RE LAYING OUT THE CROSSPIECES.

THEY'VE GOT THEIR TENONS ON THEM.

AND I GUESS YOU WANT THESE TO BE REALLY GOOD AND DRY.

YEP.

THESE ARE PRETTY DRY.

SOMETIMES THEY'RE A LITTLE BIT WET, BECAUSE YOU DON'T WANT TO PUT THEM TOGETHER TOO WET.

THEY'LL SHRINK OR EXPAND.

YEAH.

WE HAVE THESE VERY DRY, AND THEN THESE COULD BE JUST SLIGHTLY MOIST-- THE UPRIGHTS CAN-- BUT THE RUNGS HAVE GOT TO BE POSITIVELY DRY.

ALL RIGHT.

IT LOOKS LIKE YOU'RE WORKING VERY THOUGHTFULLY THERE.

I SEE... RUBBER BANDS?

YES.

I'VE USED THESE RUBBER BANDS HERE TO HOLD THESE HERE IN PLACE SO THAT THEY WON'T TWIST.

I GOT YOU.

I GOT YOU.

BECAUSE I GOT THESE MARKS ON HERE.

WELL, HERE.

LET ME DO ONE, TOO.

THIS IS GREAT.

I KNOW THEY'VE BEEN MAKING RUSTIC FURNITURE FOR 200 YEARS AT LEAST.

I DON'T KNOW WHERE WE'D BE WITHOUT RUBBER BANDS AND SOME MASKING TAPE.

YOU'VE GOT TO HAVE YOUR MASKING TAPE.

WELL, THAT'S ONE THING I'VE DISCOVERED-- YOU KNOW, FIGURING OUT-- YOU DON'T WANT TO CUT THE PIECE, BUT YOU WANT TO KIND OF VISUALIZE WHERE IT IS, SO YOU PUT MASKING TAPE AROUND THE LENGTH OF IT, AND EYEBALL IT, AND KIND OF IMAGINE THIS THING BEFORE YOU COMMIT.

YES.

WE'RE TRYING TO GET A GENERAL IDEA BEFORE WE START WHACKING AWAY.

ALL RIGHT.

SO, TEMPORARY ASSEMBLY HERE.

AND AS LONG AS THE ARROW'S POINTING HERE GOOD AND IF THESE ARE POINTING 1, 2, 3, AND I'VE GOT THEM NUMBERED, AND THEY'RE ALL POINTING THE SAME WAY, THEN I CAN TAKE AND MARK THEM.

SO YOU DON'T WANT THESE TO ROTATE ALONG THEIR AXIS BECAUSE THE TENON MIGHT BE COCKEYED?

YES.

HERE'S ONE HERE THAT'S BENT.

I SEE.

ALL RIGHT.

SO NOW YOU JUST MARK ON THE SIDES, AND THAT WILL GUIDE YOUR AUGER BIT?

YES.

ONCE I'M HAPPY WITH THE WAY THEY ARE, I CAN MARK THE TOP AND BOTTOM.

AND THESE ARE THE TRICKS OF WORKING WITH NATURAL SHAPES, OF COURSE-- YOU NEVER KNOW WHERE EXACTLY THAT TENON IS GOING TO GO.

THAT'S RIGHT.

SO YOU'VE GOT TO MARK IT AS YOU GO ALONG.

TRY AND MAKE SURE YOU GET A GOOD ANGLE ON THERE.

AND THE VERTICAL ANGLES-- IF IT'S TILTING THIS WAY, I GUESS YOU'D JUST HAVE TO CAMBER THAT.

THIS ONE LOOKS LIKE IT GOES INWARDS JUST A LITTLE BIT.

SO I'LL HAVE TO REMEMBER TO DRILL THIS ONE, INSTEAD OF RIGHT STRAIGHT TO THIS ONE, ANGLE IT IN A LITTLE BIT.

THAT'S THE TRICK OF IT, THE CHALLENGE OF IT.

ALL RIGHT.

I SEE.

AND HERE'S THE BRACE RIGHT HERE, I SEE.

THIS IS... OU'RE GETTING AT THE STAGE RIGHT NOW-- IT'S MARKED.

YOU CAN CLAMP THIS UP AND START THE BORING PART.

BUT I SEE ON THIS ONE HERE... WE ALREADY HAVE ONE DRILLED OUT HERE.

YEAH.

YOU'VE DONE SOMETHING AROUND THE OPENING THERE.

WHAT'S GOING ON WITH THIS?

WE BEVELED IT WITH THIS KNIFE TO KEEP THE WOOD FROM SPLITTING SO THERE'S NOT PRESSURE TO SPLIT IT ALL THE WAY THROUGH, BECAUSE IT'S AN AWFUL TIGHT FRICTION FIT.

WE DON'T USE ANY GLUE.

SO I BEVEL FRONT AND BACK SO WHEN WE PUSH THIS TENON IN, IT WON'T TEAR IT OR PUT PRESSURE TO SPLIT IT ALL THE WAY THROUGH THE UPRIGHT.

WHAT ELSE CAN YOU DO TO KEEP IT FROM SPLITTING?

WELL, WE MAKE SURE WE PUT THE TENON PART UNDER A KNOT SO IT IS KIND OF LIKE A NATURAL BRACE THERE, WHERE IT WON'T POP AND CRACK UP.

SO THE CRACK CAN'T GO THROUGH THERE?

RIGHT.

ABSOLUTELY.

A NATURAL PEG.

ALL RIGHT.

NOW WHAT I'M GOING TO ASK YOU TO DO IS SKIP THE BORING PART BECAUSE WE'VE GOT THE TENONS.

WE KNOW HOW TO BORE A HOLE.

LET'S JUST SEE HOW THE ASSEMBLY GOES, IF YOU WANT TO DO ONE OF THESE SIDES HERE.

AND I'LL HELP CLEAR THE DECKS.

TOOLS END UP ALL OVER THE PLACE HERE.

IT'S NOT THE FIRST.

1, 2, 3.

SO THIS IS GOING TO BE THE FRONT YOU'RE GOING TO DO?

ABSOLUTELY.

THE FRONT UPRIGHT.

MM-HMM.

WE LOOK FOR OUR ARROWS.

LET'S SEE.

NOW, I'VE GOT AN ARROW ON THIS END POINTING THIS DIRECTION.

YEP, AND WE WANT THESE COMING IN FROM THIS SECTION.

AND THAT'S CORRECT?

ALL RIGHT.

SO THAT ROCKS IN THERE.

AND WE PUT THIS HERE, AND WE WANT TO TAP IT A LITTLE.

ALL RIGHT, AND THEN WHAT DO YOU DO?

AND THEN CHECK TO MAKE SURE THE ARROW'S GOING THE RIGHT WAY.

SHE HAS NUMBER 2.

ALL RIGHT, SO TAP IN A LITTLE BIT, AND THEN LOOK AND SEE.

EASIER TO DO IT WHEN IT'S JUST LIGHTLY TAPPED IN.

YEAH.

OTHERWISE, IF IT'S IN THERE TOO MUCH, THEN IT'S ALL HAPHAZARD FROM THERE.

HERE'S NUMBER 3 RIGHT HERE.

THERE IS METHOD IN THIS MADNESS.

AH, THERE IS A METHOD TO OUR MADNESS.

AND THAT ARROW-- ALL RIGHT.

GREAT.

AND I SEE HOW THEY'RE ALL PRETTY WELL ALIGNED TO GO INTO THE NEXT ONE.

VERY GOOD.

I'LL JUST DRIVE THESE IN.

ALL RIGHT.

I'LL GET OUT OF THE WAY.

AND THAT'S THE BIG SEAT POST.

THAT'S IN ASH.

YEP.

WE WANT THIS FIRST.

THE BIGGEST ONE IS FOR OUR SEAT TO SIT ON.

AND WE WANT ANOTHER BIG ONE AT THE BOTTOM RELATIVELY IN BETWEEN THE 2 SIZES BECAUSE THAT'S WHERE PEOPLE WOULD GENERALLY PUT THEIR FEET ON.

PUT THEIR FEET.

OK.

THEY'RE GOING TO WEAR NICE WEAR PATTERNS IN THAT APPLE.

THERE WAS AN ORCHARD, I GUESS YOU TOLD ME, THAT WENT OUT.

YES.

SHARON SPRINGS ORCHARD, WHERE THEY'RE CUTTING DOWN THESE TREES, HAD THESE DEAD APPLE TREES, AND WE'RE FORTUNATE ENOUGH TO HAVE THEM TO MAKE THIS WONDERFUL RUNG STOCK WITH.

REALLY GREAT WOOD.

I LOVE WORKING WITH APPLE, BUT IT'S HARD-- ALWAYS, LIKE, AFTER A BIG ICE STORM OR SOMETHING LIKE THAT THAT YOU GET IT.

ARE YOU READY FOR THE CLAMPS?

YES, I THINK WE'RE GOING TO USE SOME CLAMPS NOW.

ALL RIGHTIE.

I WILL HELP YOU.

YOU WANT TO HANG IT OFF THE END A LITTLE BIT?

YES.

IT HELPS SO THESE THINGS AREN'T KNOCKING AGAINST ON THE BENCH.

ALL RIGHT.

SOMETIMES YOU GET AN ICE STORM, AND IT'S VERY SAD, YOU KNOW-- THIS WONDERFUL ORCHARD TORN UP BY THAT.

LUCKILY, WE GET TO MAKE SOME USE OUT OF THE WOOD.

THAT'S TRUE.

IT'S NOT A COMPLETE LOSS.

AND SO, ALL RIGHT.

SO WE JUST KEEP TORQUING IT ON UP?

CLAMP THESE TOGETHER.

THIS ONE'S SHOULDERED HERE.

DO I NEED TO HIT THAT?

OK, I'LL WHACK IT BACK.

YOU'VE GOT A GOOD ANGLE TO HIT THAT.

BECAUSE I KNOW YOU WANT TO KEEP-- THE SHOULDERS, THAT BEVELED SHOULDER, PUSHING INTO THAT POCKET COULD SPLIT THIS, I RECKON.

YES, THAT'S TRUE.

HAVE YOU GOT ENOUGH CLEARANCE THERE?

BECAUSE YOU'RE GETTING THE SAME THING HERE.

HE NEEDS TO WHACK FROM THIS END HERE.

ALL RIGHT.

NOW WE'LL TORQUE ON UP.

IT'S JUMPING OFF IT.

ALL RIGHT, AND I THINK I'VE ABOUT GOT THE TOP THERE TOGETHER.

AND SO NO GLUE.

JUST A REALLY, REALLY-- FRICTION FIT.

AND IT'S WONDERFUL.

LET'S SEE.

I SEE HOW FLAT THE WHOLE THING IS LYING IN ABOUT THE RIGHT PLANE THERE.

AND WE'LL TAP THAT ONE, TOO, A LITTLE BIT MORE.

YEAH, BRING THAT ONE TO THE CENTER.

ALL RIGHT.

I GOT IT.

NOW, I KNOW YOU'VE GOT MORE PRECISION ADJUSTMENT, BUT I'M GOING TO ASK YOU TO JUST KEEP ASSEMBLING IT WITH A LITTLE BIT LOOSER JOINTS, IF THAT'S ALL RIGHT, BECAUSE I WANT TO MAKE SURE WE GET TO SEE THIS WHOLE PROCESS THROUGH.

HERE'S ONE WHERE WE'VE ALREADY DRILLED IT OUT AND MARKED... 7, 8, AND 9.

UH-HUH.

AND YOU'VE ALREADY GOT A BACK ASSEMBLY.

NOW, THIS I REALLY ADMIRE IN YOUR CHAIRS.

THESE ARE JUST WONDERFUL, THE WAY THIS IS KIND OF SCOOPED OUT HERE.

NICE CONTOUR FOR THE BACK.

OH, YEAH, IT'S GREAT.

AND YOUR SPINE GOES RIGHT IN THERE AND JUST FEELS SO COMFORTABLE.

BUT THIS IS A NATURAL FORK HERE, BUT DID YOU PUT THAT BEND IN THERE, THAT SWEEP?

YES.

HERE, I HEATED IT UP WITH A TORCH AND BENT THESE.

THESE, BECAUSE THEY BEND, I JUST TURNED THEM SIDEWAYS ENOUGH SO THEY BEND A LITTLE BIT FOR THE BACK, BUT THESE I DO HAVE TO BEND SOMETIMES.

WELL, LET'S SEE HOW THIS GOES.

NOW, DOES THIS GO IN HERE?

YES.

ALL RIGHTIE.

AND...I'LL SET IT.

OOP.

OOP.

THAT HAPPENS.

YEP.

THAT'S PART OF THE BACK THERE.

FRICTION FIT.

AND AGAIN, THESE AREN'T GLUED EITHER.

NO, BUT ONCE THEY GET DRIVEN IN AND LOCKED IN, IT WON'T COME APART ANYMORE.

YEAH.

IT WON'T MOVE AT ALL.

ALL RIGHT.

YEP.

THERE WE GO.

GOT THAT TAPPED IN.

ALL RIGHT.

NOW... LAY THAT DOWN ON THE BENCH, JUST LIKE THAT.

JOIN IT TO THE OTHER SIDE.

LET'S SEE... HAVE WE GOT THIS TURNED OVER?

I WAS THINKING, SAYING, BOY, THAT'S GOING TO BE A SETTEE.

WHAT HAVE WE GOT HERE?

OH, LOOK.

SO THEY ALL LINE UP.

AND THAT'S WHAT THOSE NUMBERS DO-- KEEPING ONE FROM TWISTING, RIGHT?

[HAMMERING] IF WE DID EVERYTHING WE WERE SUPPOSED TO.

AH.

VERY GOOD.

WATCH YOUR HAND.

YOU'VE GOT A RUBBER MALLET THERE, BUT AGAIN, USING THE CLAMPS, YOU'LL TRY AND GET THESE TENONS COMING SO THAT THEY... GO RIGHT UP CLOSE BUT NOT ALL THE WAY TO THE SHOULDERS, TO THAT BEVELED SHOULDER ON EACH PIECE.

RIGHT, BECAUSE THEN IT COULD CRACK IT OR SPLIT IT.

SO WE WANT TO MAKE SURE TO GET AS CLOSE AS WE CAN.

NOW WE USUALLY LIKE TO TRIM THE TENONS SO IT DOESN'T MAR ANYBODY ON THE LEGS.

ALL RIGHTIE.

I'M GUESSING I'M IN YOUR WAY.

SO LET ME GET OUT OF HERE.

OH, NOT AT ALL.

HA HA HA!

THIS IS GREAT.

SEE, WE ALREADY HAD BEVELED THIS SIDE OVER HERE.

AND NOW I'M JUST GOING TO COME AT IT FROM THE OTHER ANGLE HERE AND TAKE THIS CHISEL, AND WE JUST WANT TO ROUND THESE TENONS A LOT SO THEY'RE NOT RUBBING ON OUR LEGS, THESE LITTLE NUBS.

AND THEN WE'LL TOUCH IT OFF WITH SOME SANDPAPER WHEN WE COME TO THE MORE FINISHING ASPECTS.

AND I LOVE--IN THE DESIGN, YOU USE CURVED PIECES WHERE PEOPLE PUT THEIR LEGS BACK HERE.

LEGS, YEAH.

SO THEY CAN TUCK THEM IN A LITTLE BIT.

YEAH.

VERY NICE.

DAD HAS SOME GREAT IDEAS.

WELL, IT REALLY SITS WONDERFULLY ALREADY.

IT'S QUITE STOUT EVEN THOUGH WE HAVEN'T DRIVEN THE TENONS IN ALL THE WAY.

BUT NOW WE LIKE TO LEVEL IT.

LEVEL?

EVEN THOUGH I DARE YOU TO FIND A HOUSE HERE IN THE ADIRONDACKS THAT HAS A LEVEL FLOOR.

YES.

THERE'S VERY FEW LEVEL FLOORS AROUND HERE.

THIS IS A PIECE OF MARBLE MY FATHER GOT FROM THE WORLD'S FAIR IN NEW YORK CITY MANY YEARS AGO, AND IT'S ALWAYS LEVEL, NO MATTER IF IT'S MOIST...

PROBABLY FOR MAKING FUDGE OR SOMETHING ON IT, YEAH.

OR DRY OUTSIDE, AND SO IT'S OUR SACRED PIECE OF MARBLE, WE CALL IT.

HA HA HA!

SACRED MARBLE.

AND I TAKE A LEVEL, A LITTLE WEDGE, AND THEN I WEDGE IT UP UNTIL I LIKE IT.

MM-HMM.

AND THEN I JUST MARK IT HERE WITH A SCRIBER ABOUT THE HEIGHT OF WHERE THERE'S AN OPENING.

OH, SO YOU TAKE THE BIGGEST GAP.

YES, THE BIGGEST GAP, AND I JUST MARK IT ALONG ALL THE WAY AROUND WITH THIS SCRIBER, AND THEN WE CUT IT, AND THEN WE ALWAYS LEAVE THE SCRIBE LINES SO THAT IT'S EASY TO LEVEL, INSTEAD OF CUTTING THE SCRIBE LINES AWAY.

L RIGHT.

TAKE IT DOWN TO THE SCRIBE MARK.

VERY GOOD.

NOW, I GUESS YOU HAVE A LITTLE BIT OF LEVELING TO DO ON THESE TOP SEAT POSTS, BUT YOU'VE GOT TO PUT A SEAT IN HERE NOW.

UNLESS THIS IS A POTTY CHAIR, YOU'VE GOT TO DO SOMETHING AT THIS STAGE.

SO WHAT'S NEXT?

YES.

WELL, I HAVE A PIECE OF BUTTERNUT HERE THAT WE HAVE, AND WHAT I USUALLY DO WHEN I MAKE THE SEATS IS I TAKE A PENCIL HERE, AND I JUST MARK THE LINES UNDERNEATH WHERE I CAN CUT THESE TABS DOWN.

LIKE THIS.

UH-HUH.

Skye: SO IT'LL SIT ON THE RUNGS.

NOW COME OVER HERE TO THE CHOPPING BLOCK.

AH, YES.

WELL, THIS IS GREAT.

THIS IS GREAT.

RUNNING A CHAIRMAKING SHOP, YOU ALWAYS HAVE A PLACE TO SIT.

YES.

YES.

THAT'S RIGHT.

I TAKE SITTING DOWN ON A JOB VERY SERIOUSLY.

VERY NICE.

THEN I'LL CHOP OUT THESE TABS.

SO, JUST TO GET A PLACE TO SIT DOWN ON THE RUNGS ON EITHER END.

SO YOU USE 3 PIECES THERE.

AND ONCE I'VE GOT THESE TABS CUT, I'LL GO BACK AND FORTH NORMALLY BETWEEN HERE AND THE FRAME, TRYING TO PUT IT ON SO IT WON'T ROCK.

AND ONCE IT WON'T ROCK ON A FRAME, THEN I CAN CONTOUR OUT THE SEAT.

AH.

AND AGAIN, WITH THE HATCHET.

HE'S DOING A PIECE LIKE THAT, A HATCHET'S CERTAINLY THE BEST TOOL FOR THAT JOB.

I SEEM TO BE COMFORTABLE WITH IT.

I KNOW SOME FOLKS HAVE USED SCOOP ADZES AND THINGS.

I GUESS I'M JUST USED TO A HATCHET.

WELL, YOU'VE GOT A LONG-GRAIN PIECE.

EASY TO HOLD IT RIGHT THERE AND GET IN THERE.

SO THAT'S GREAT.

SO, THAT'S CHOPPED OUT NOW, AND SKYE, YOU'RE ALREADY SITTING ON THE-- WE WANT TO TAKE THE ROUGH MARKS OUT OF IT.

SO WE TAKE THE SHAVING HORSE HERE, AND WE TAKE A BEVELED DRAWKNIFE HERE, AND WE'VE GOT THE BUTTERNUT SLAB.

AND HE'S ALREADY GOT SOME PIECES ROUGHED IN HERE FROM THE HATCHET.

AND YOU JUST WANT TO SKEW THROUGH IT, WHICH IS A SIDEWAYS MOTION HERE.

SO...OH, I SEE.

YOU'RE KIND OF PULLING IT ON A DIAGONAL.

RIGHT.

ON A DIAGONAL BECAUSE WE'RE TRYING TO GET RID OF THOSE HATCHET MARKS SO THEY'LL SIT A LITTLE BIT MORE FLATTER ON THERE.

ALL RIGHT.

AND THEN ALSO WITH A SPOKESHAVE, WE'LL TAKE TO THE CONTOURING OF THE SEAT AREA, AND WE WANT TO MAKE SURE OUR-- SO YOU BUM FITS IN THERE.

THAT'S RIGHT.

YOU'VE GOT, AGAIN, KIND OF A CONVEX SPOKESHAVE, WORKING DOWN THE GRAIN IN BUTTERNUT.

COME AT IT FROM BOTH SIDES.

YES, BUTTERNUT.

THIS IS A NICE, LIGHT WOOD TO GO THROUGH.

LUCKILY, THIS HAS NO KNOTS, AND THE GRAIN'S GOING NICE AND SMOOTH.

ALL RIGHT, THAT'S THE SEAT.

NOW YOU'VE GOT TO PEG THAT ON.

YOU'VE GOT A LITTLE PEG DEAL HERE, IT LOOKS LIKE.

WE'VE JUST SPLIT OUT SOME WOOD HERE, SOME ASH.

YOU'VE JUST GOT A STEEL PLATE WITH A HOLE THROUGH IT, A LITTLE UNDERCUT.

YEAH, ALL RIGHT.

AND I JUST DRIVE IT THROUGH A BIGGER HOLE FIRST, AND I REALLY HAVE TO WORK IT ON DOWN THROUGH THE HOLES.

OH, SO YOU USE A SEQUENCE OF HOLES THERE.

AS LONG AS MY WOOD'S ABSOLUTELY DRY, I CAN GET A NICE PEG THAT WON'T SHRINK.

AH, AND THAT'S IMPORTANT.

ALL RIGHT, SO YOU GET THE PEGS TO PEG.

AND I HEARD IT POP ON DOWN THERE.

AND THERE'S YOUR PEG OF PERFECTION.

AND JUST GO WORKING ALONG THERE.

WE TAKE IT DOWN A COUPLE OF SIZES, WE DRILL HOLES, AND GET IT ANGLED IN THERE.

SO YOUR SEAT WILL NEVER COME LOOSE, AND THOSE PEGS ARE GLUED, I TAKE IT.

YEP.

THE PEGS ARE GLUED.

THAT'S THE ONLY PART WHERE WE DO USE GLUE.

WHILE I WAS SITTING HERE, I NOTICED THIS.

THIS IS ALL SCALLOPED.

THIS IS WILD.

IS THIS SOMETHING YOU DO, TOO?

THIS IS SOMETHING ELSE THAT I DO.

WE ALL DO THE GOUGE WORK, BUT WE HAVE DIFFERENT STYLES.

THIS IS A LITTLE LEFT-TO-RIGHT-- OR A RIGHT-TO-LEFT RATHER MOTION WITH THE GOUGE.

WELL, I'VE GOT TO SEE.

SHOW US SOME OF THAT THERE.

ALL RIGHT.

BECAUSE I THINK THE BEST WAY TO UNDERSTAND IS TO TAKE A LOOK.

AND IF WE CAN DO THIS, WE WON'T HIT EACH OTHER... YEAH.

WHACK.

WHACK EACH OTHER AS WE UNDO THIS.

I USUALLY PUT IT IN LIKE THIS.

OK. AND...IS THIS SOMETHING YOU USE A MALLET ON?

OR DO YOU JUST PUSH IT?

I JUST PUSH IT.

I USE THE FORCE.

I'VE GOT THIS LITTLE LIP HERE WHERE I CAN PUT MY THUMB ON THIS GOUGE AND JUST ARM IT IN THERE.

AND WE WANT TO GO RIGHT TO LEFT WHEN YOU CARVE THROUGH IT.

I'LL FEEL IT EVERY OTHER COUPLE OF SWIPES TO SEE IF I'VE GOT SOME BURRS THERE THAT I NEED TO TAKE CARE OF.

YEAH.

CHERRY WOOD'S NICE LIGHT WOOD, BUT IT DARKENS UP AFTER A WHILE.

YOU'RE GOING TO END UP WITH THIS WONDERFUL TEXTURED SURFACE.

YES, AND THIS IS WHAT WE END UP WITH AFTER A WHILE, RIGHT.

ALL RIGHT.

SO YOU'RE DOING SOME OF THESE-- YOU'VE GOT 120 CHAIRS TO DO.

LET'S TAKE A LOOK AT THE ONE YOU'VE GOT RIGHT HERE AGAIN.

MOST OF THEM ARE GOING TO LOOK LIKE THIS, BUT YOU'RE GOING TO DO SOME WITH THAT TEXTURED SEAT ON IT AS WELL?

YES.

SKYE WILL DO A COUPLE OF TEXTURED SEATS, I THINK, TO MAKE IT UNIQUE UP THERE, YOU KNOW.

AH, THAT'S GOOD.

SO YOU HAVE A MIX OF THINGS.

WELL, LISTEN, THERE'S JUST A HUGE VARIETY IN RUSTIC FURNITURE.

I WONDER IF WE COULD TAKE JUST A MINUTE AND LOOK DOWN AT THE GALLERY AND SEE WHAT YOU'VE GOT.

WE CERTAINLY CAN.

WE HAVE SEVERAL OTHER PIECES OF RUSTIC ART DOWN THERE, TOO.

LET'S GO TAKE A LOOK.

EXCELLENT.

LET US PROCEED.

WOW.

ALL RIGHT.

THIS IS THE REAL OLD THING.

THIS IS BEAUTIFUL.

WHOA.

Barry: THAT'S RIGHT, ROY.

IT'S MADE AROUND 1850 WITH RHODODENDRON ROOT, AND IT WAS IN A HOUSE IN LONG LAKE.

IT'S TREMENDOUS.

NOW, WHY IS IT SO DARK?

ACTUALLY, SOME PEOPLE THINK THIS IS A PAINT, BUT IT'S ACTUALLY THE VARNISH THEY USED TO USE BACK THEN, AND OVER TIME, IT DARKENS WITH A COLOR.

WELL, IT'S ENTITLED TO, AFTER 175 YEARS.

THIS IS A VERY FAMOUS SET NOW-- THE SETTEE, THE 2 CHAIRS, AND THE TABLE.

I'VE SEEN THIS IN BOOKS.

THIS IS WONDERFUL.

YES, 2 VERY FAMOUS BOOKS.

THIS IS TREMENDOUS.

AND THIS IS A GREAT EXAMPLE OF HOW THEY COMBINED THE GROTESQUE, THE GNARLY STUFF, THE WILD, WITH THE VERY CONTROLLED MOSAIC WORK ON THE TOP.

I LOVE THAT.

YES, I DO LOVE THAT MOSAIC WORK.

IT'S BEAUTIFUL.

THIS IS NOT A LOST ART.

ABSOLUTELY NOT.

IN FACT, WE HAVE ANOTHER BEAUTIFUL PIECE OVER HERE.

AH, AND IS THIS A FAMILY PIECE RIGHT HERE?

YES.

MY CHILDREN HELPED ME MAKE THIS PIECE.

AND THE FRAME IS MADE OUT OF YELLOW BIRCH, WHERE WE'VE KEPT THE BARK ON BY HARVESTING AFTER THANKSGIVING.

AND WE HAVE SOME CHERRY SHELVES, CURLY CHERRY SHELVES, AND THE BACKING HERE IS JUST SOME DRY WHITE BIRCH BARK THAT WE GOT OFF SOME DEAD WHITE BIRCH TREES.

AH, OK. AND THEN THE MOSAIC WORK ON THE TOP HERE, AND AGAIN, YOU HARVEST THIS WOOD DURING THE WINTER WHEN THE SAP IS TIGHT, AS THEY SAY, SO THE BARK WILL STAY ON.

IT TENDS TO KEEP THE BARK ON.

ALL RIGHT.

AND BEAUTIFUL DRAWS HERE, DOORS TO YOUR CABINETS.

Skye: AND APPLE HINGES.

I SEE THAT.

I NOTICED THAT.

IT'S CUT SO THAT IT IS SELF-CLOSING.

WONDERFUL WORKMANSHIP IN THIS, BARRY.

IT'S TREMENDOUS.

AND THIS ONE, TOO, HERE.

OH, MY GOSH.

WHAT'S THIS BURL?

YES.

THIS IS CHERRY BURL ON THE TOP HERE, ROY.

AND ON THE BOTTOM HERE, WE HAVE A BEAUTIFUL PIECE OF YELLOW BIRCH THAT WE HARVESTED TO GO ALONG WITH IT.

AND THIS IS SOMETHING WE'D HARVEST OUT OF THE ROCKS AND THE DIRT, AND HOWEVER, WE WERE HARVESTING IT WHEN THERE'S SNOW ON THE GROUND.

SO WHEN WE WERE CHIPPING THROUGH, WE WERE TRYING NOT TO MAR UP THAT BARK SO MUCH.

WOW.

OUT IN THE SNOW.

AND THIS, AGAIN, WHAT IS THIS ON THE FRONT?

THIS APRON IS MADE OUT OF YELLOW BIRCH HERE, LITTLE ROOTS OF YELLOW BIRCH, AND THEN ALSO SOME CURLY MAPLE HERE.

MMM.

IT'S BEAUTIFUL, BUT I TELL YOU, THIS HAS GOT TO BE A FAVORITE PIECE RIGHT HERE.

A ROCKING CHAIR IS ALWAYS SURE TO PLEASE, AND THIS IS A TREMENDOUS USE OF WOOD THERE, PARTICULARLY IN THE BACK.

LOOK AT THAT.

WHAT IS THIS HERE?

THIS IS APPLE HERE ACTUALLY, WITH THE BEAUTIFUL DIFFERENT COLORATION.

THIS IS A CHERRY BURL CENTER, AND SOME LOCUST PEGS.

THERE'S A BEECH ARMREST ON EITHER SIDE.

THIS IS A CURLY CHERRY SEAT, AND SOME MORE LOCUST PEGS HERE THAT WE FASTENED IT WITH.

AND IT'S SO HARMONIOUS, THE WAY IT ALL GOES TOGETHER, AND I LOVE THE CONTRAST OF THE ENDS OF THE TENONS THERE.

GOING RIGHT THROUGH THE UPRIGHTS.

YEAH.

AND THEY'RE ALL MITERED OFF LIKE YOU DO.

AND YOU CAN REALLY SEE THAT HOURGLASS DESIGN THAT YOU DO.

OH, IT'S TREMENDOUS.

THIS IS AN ABSOLUTELY BEAUTIFUL, BEAUTIFUL ROCKER HERE.

ALL RIGHT.

NOW THIS, THOUGH, HAS GOT TO BE A FAVORITE, TOO.

THIS IS...AGAIN, A LOT OF BURL WOOD ON HERE, AND THIS--SKYE, YOU CALL THIS THE "MILK AND COOKIES" CHAIR.

IS THAT RIGHT?

YES.

I LOVE MILK AND COOKIES, AND I LOVE THIS CHAIR.

SO YOU'VE GOT--WHAT IS THIS RIGHT HERE ON THIS ARM?

THIS ARMREST FOR THE MILK IS A CHERRY BURL ARMREST.

AND THIS IS A HOLLOWED-OUT CHERRY BURL BOWL FOR THE COOKIES.

WELL, THIS IS CERTAINLY WHAT YOU NEED, I THINK, IS YOU ARE GOING TO BE SITTING-- AND IT'S WONDERFUL.

I THINK ALL OF THE WORK YOU'VE GOT HAS THIS LOOK-- IT'S STILL ORGANIC, IT'S STILL GROWING, LIKE IT'S GOING TO SET ROOT AGAIN.

WE TRY TO DO THAT.

OH, IT'S GREAT.

WELL, HEY, BARRY GREGSON, THANK YOU FOR SHOWING US AROUND.

WE SURE APPRECIATE IT.

SKYE GREGSON.

ROY, IT'S BEEN A PLEASURE.

THANK YOU FOR LETTING ME WORK ALONG WITH YOU.

HEY, AND THANK YOU FOR JOINING ME HERE IN THE ADIRONDACKS.

THIS HAS BEEN ROY UNDERHILL HERE IN "THE WOODWRIGHT'S SHOP."

WE'LL SEE YOU NEXT TIME.

SO LONG.

TO LEARN MORE ABOUT "THE WOODWRIGHT'S SHOP" AND TRADITIONAL WOODWORKING, VISIT PBS ON-LINE.

YOU CAN FIND US AT pbs.org.

CAPTIONING MADE POSSIBLE BY U.S. DEPARTMENT OF EDUCATION CAPTIONED BY THE NATIONAL CAPTIONING INSTITUTE --www.ncicap.org-- MAJOR FUNDING FOR "THE WOODWRIGHT'S SHOP" IS PROVIDED BY... ROY UNDERHILL IS THE AUTHOR OF "THE WOODWRIGHT'S SHOP" AND OTHER BOOKS ABOUT TRADITIONAL WOODWORKING, PUBLISHED BY THE UNIVERSITY OF NORTH CAROLINA PRESS AND AVAILABLE AT BOOKSTORES AND LIBRARIES.