Windsor Highchair With Curtis Buchanan, Pt.1

Announcer: 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."

HEY.

HELLO AGAIN.

WELCOME BACK TO "THE WOODWRIGHT'S SHOP."

I'M ROY UNDERHILL.

SO GLAD YOU COULD BE WITH ME AGAIN TODAY BECAUSE OUR GOOD FRIEND CURTIS BUCHANAN IS HERE.

HE'S GOING TO SHOW US ABOUT MAKING THIS WONDERFUL WINDSOR CHAIR.

CURTIS, WELCOME.

THANK YOU, ROY.

GREAT TO SEE YOU.

GOSH, THIS IS A BEAUTY HERE.

AND THIS IS QUITE A TOUGH THING TO DO IN THE LITTLE TIME WE HAVE TOGETHER, SO WE'RE GOING TO TAKE 2 TIMES, IS THAT RIGHT?

RIGHT.

YEAH.

WELL, TELL ME ABOUT IT.

WHAT DO YOU GOT?

WHAT ARE YOUR PARTS HERE?

WELL, WE'VE GOT THE COMB OF THE CHAIR UP HERE, AND THE SPINDLES, THE ARM RAIL, AND THE SEAT, AND THEN THE UNDERCARRIAGE, WHICH ARE THE LEGS AND THE STRETCHERS.

OH, BUT IT ALL COMES TOGETHER SO BEAUTIFULLY.

THIS IS WONDERFUL.

AND WHAT KIND OF WOOD DO WE HAVE DOWN HERE?

THIS IS HARD MAPLE, OR SUGAR MAPLE.

UH-HUH.

AND IT'S CHOSEN FOR ITS TIGHT GRAIN.

BE ABLE TO GET NICE CRISP, CLEAN LINES IN THE TURNING.

I ADMIRE YOUR TURNING.

I'M GOING TO TALK TO YOU ABOUT THAT IN A LITTLE BIT, BECAUSE MY TURNING IS NOWHERE-- MY TURNING IS SO LAME.

WE'RE GOING TO FIGURE OUT HOW TO DO THAT JUST THAT WELL.

AND WHAT HAVE WE GOT ON THE SEAT HERE?

THIS IS EASTERN WHITE PINE HERE, AND IT'S CHOSEN FOR ITS SOFTNESS.

SO IT'S EASY TO CARVE.

BUT THAT'S THE ANCHOR OF THE WHOLE THING.

ALL THE PIECES COME IN.

AND THAT REALLY DEFINES A WINDSOR CHAIR-- IS ALL THE PARTS ANCHOR AT THE SEAT.

AH.

REALLY?

OK.

IF IT DOES THAT, IT'S A WINDSOR.

ALL RIGHT.

VERY GOOD.

AND THEN WE MOVE ON UP HERE.

WE'VE GOT SOME POSTS LIKE WE HAD ON THE LEGS.

THEY'RE TURNED ON A LATHE.

RIGHT.

MM-HMM.

THESE ARE TURNED.

AGAIN MAPLE.

AND THEN THESE SPINDLES, THOUGH, WHAT ARE THEY?

WELL, THESE ARE WHITE OAK.

I THINK THERE MIGHT BE A LITTLE BIT OF RED OAK IN THERE.

IT CAN BE HICKORY OR ASH ALSO, AND IT'S SPLIT, OR RIVED, STRAIGHT FROM THE LOG, AND THEN SHAPED WITH A DRAWKNIFE, AND THEN THESE 2 PARTS ARE STEAMED AND BENT.

REALLY?

OK.

SO THE CREST AND THE ARM RAIL.

NOW, THIS IS TOO MUCH ALL, AGAIN, TO DO IN JUST OUR LITTLE TIME TOGETHER.

SO WE'RE JUST GOING TO DO THE UNDERCARRIAGE.

IS THAT RIGHT?

FROM THE SEAT DOWN.

RIGHT.

DO THE UNDERCARRIAGE TODAY.

ALL RIGHT.

WELL, LET'S LOOK AT THAT TURNING, BECAUSE THIS IS...

IT'S JUST MAGNIFICENT, CURTIS.

I SEE STUDENTS-- I KNOW YOU TEACH A LOT WINDSOR CHAIRMAKING-- AND I CAN SPOT YOUR STUDENTS BY JUST THIS BOLD QUALITY THAT YOU HAVE TO THE TURNING.

WHAT ARE THE PARTS HERE THAT I'M LOOKING AT?

WELL, RIGHT HERE WOULD BE THE BEAD OF THE TURNING.

THIS IS A FILLET, AND THIS IS A COVE, AND THIS IS A BIRD'S BEAK, AND THIS IS THE LOWER BALUSTER RIGHT HERE.

AND YOU TRY TO MAKE THEM ALL FLOW TOGETHER, BUT ALSO BE CRISP AND CLEAN WHERE YOU CAN VIEW THEM INDEPENDENT AND INDIVIDUAL.

AND, OF COURSE, THE MAPLE AND A SHARP TOOL ARE WHAT ENABLE YOU TO DO THAT.

THAT'S THE TICKET.

ALL RIGHT.

WELL, WE'RE GOING TO GET A LESSON ON THAT ON MY LATHE NOW.

I'M GOING TO TREADLE ON THE TREADLE LATHE HERE.

THAT'S GOOD.

THAT SOUNDS GOOD TO ME.

I HOPE SO.

HA HA!

I'LL KEEP IT GOING.

NOW, YOU NEED TO GO ANY FASTER, YOU JUST KIND OF WHACK ME ONE.

OK.

I'LL PUT MY GLASSES ON HERE.

SO WE'VE GOT SOME MAPLE IN HERE.

I'LL TAKE A ROUGHING-OUT GOUGE FIRST, AND I'LL JUST TRUE IT UP, LIKE THAT.

JUST KEEP IT UP OVER THERE.

ALL RIGHT.

THEN I'LL MARK OUT THE TOE, AND THEN HERE'S THE BEAD, RIGHT THERE.

NOW I'LL DO A "V" CUT.

YOU'RE USING THE LONG POINT OF THE SKEW.

RIGHT.

USING THE LONG POINTS FOR THESE "V" CUTS, AND THEN, UH... OOP.

I'VE GOT TO PEDAL A LITTLE HARDER HERE.

YEAH, A LITTLE FASTER THERE.

STARTING TO LOSE POWER.

I'M GOING TO CHANGE LEGS HERE.

THERE WE GO.

ALL RIGHT.

THEN I'M GOING TO CUT A COVE HERE... GET RID OF A LITTLE BIT OF BULK MATERIAL WITH THIS MOVE.

UH-HUH.

YOU'VE GOT A REAL SHORT BEVEL ON THAT GOUGE THERE.

YEAH.

THAT ENABLES ME TO GET MORE CONTROL OFF OF IT.

HE SAID TOO SOON.

I SAID TOO SOON, RIGHT.

WATCH IT MOVE WITH ME THERE.

THAT'S ACTUALLY MADE THAT FILLET A REAL GOOD SIZE THERE.

JUST WHAT I WANTED TO DO.

YEAH, YOU MEANT TO DO THAT.

THAT'S WONDERFUL.

I CAN SEE THE WAY YOU ROTATE THE TOOL THERE, SWINGING BOTH THE END AND ROTATING IT AS YOU DO.

YOU HAVE TO CUT DOWNHILL.

SO I CAN'T CUT BACK UP THE OTHER SIDE OF THAT COVE.

UH-HUH.

SO COMING DOWN... YEAH.

SO, THERE WE GO.

WHEW.

I HOPE THAT SPEED'S ENOUGH.

I'M GOING TO CHANGE LEGS AGAIN.

NOW THE LITTLE FILLET THAT I WAS SHOWING YOU-- I'LL CUT IT, AND I DO THAT WITH THE HEEL.

AND THAT'S A NICE, EASY MOVE.

YOU JUST ROLL IN LIKE THAT.

YEAH.

AND THEN FOR FORMING THE BEAD, I DO THAT WITH THE SKEW CHISEL.

ALL RIGHT.

I'LL GET UP SOME SPEED HERE.

YEAH, GET IT SOME SPEED WITH THIS, AND... WHOO.

YEAH.

SO JUST ROLL IT OVER?

LOOK AT THAT.

IT'S LIKE BURNISHING IT AS YOU CUT.

AND THEN I TAKE A LITTLE PRELIMINARY CUT HERE, GET RID OF SOME OF THE BULK OF THE MATERIAL, AND THEN NOW I'LL DO THE WHOLE BEAD.

NOW, THAT TOOL IS, AGAIN, SHARPENED HOLLOW.

OOH!

YEAH.

IT'S A HOLLOW GRIND, AND THEN IT'S HONED.

THAT'S WONDERFUL.

ALL RIGHT.

THAT BIRD'S MOUTH-- WILL YOU BE ABLE TO DO THAT?

YEAH.

I CAN GIVE IT A TRY HERE.

BIRD'S BEAK.

I DON'T KNOW IF I COULD DO A BIRD'S MOUTH.

BIRD'S BEAK.

HA HA HA!

A BIRD'S BEAK, YEAH.

ALL RIGHT.

IT'S JUST A MATTER OF MY LEG.

I THINK I'M GOING TO BE THE LIMITING FACTOR HERE.

WELL, I'LL SEE IF I CAN...

BOY, THIS IS THE KIND OF THING, I KNOW-- I'M WORKING ON A TREADLE LATHE HERE, BUT I KNOW YOU FELLAS-- YOU WORK WITH DON WEBER AND ALL THE FELLAS WHO WORK SPRINGPOLE LATHES, WORK WITH GREEN WOOD.

RIGHT.

A SPRINGPOLE LATHE WORKS WELL IN THAT SITUATION, WHERE WE'RE WORKING IN CENTRAL AMERICA IN OUR SUSTAINABLE FORESTRY PROJECT.

A SPRINGPOLE HAS A LOT OF POWER TO IT.

AND NOT A LOT OF THINGS TO GO WRONG OR RUST OR FOUL UP ON YOU.

AND OF COURSE, THOSE ORIGINAL WINDSORS-- WERE MADE WITH POLE LATHES.

SO, THERE'S SOME SEMBLANCE OF WHAT MINE WAS THERE.

THAT IS WONDERFUL.

AND IT'S BEAUTIFULLY, BEAUTIFULLY POLISHED THERE, AND WONDERFUL.

LET ME TAKE A LOOK AT YOUR GOUGE AGAIN JUST ONE LITTLE BIT.

AGAIN, VERY SHORT BEVEL, AND THAT'S WHAT GIVES YOU CONTROL.

BUT DEAD-FLAT ON THE BEVEL, TOO.

YEAH.

THE HONE IS FLAT.

THE HONE IS FLAT.

SAME WAY ON ALL OF THE TURNING TOOLS-- THE HONE IS ALWAYS FLAT.

WOW.

WHAT A COOL TOOL.

ALL RIGHT.

BUT IT'S NOT JUST THE TOOLS.

I COULD SAY, "BOY, IF I HAD TOOLS LIKE THAT, I COULD DO IT."

BUT IT'S TRUE--IF YOU DON'T SHARPEN THEM RIGHT, YOU'RE NOT GOING TO GET THAT KIND OF CUT.

RIGHT.

NOT JUST SHARP, BUT SHARPENED RIGHT.

SHARPENED PROPERLY.

ALL RIGHT.

SO WE DO THIS 4 TIMES.

NOW WE'RE READY TO GO AHEAD AND PUT THE SEAT TOGETHER HERE.

SO LET'S TAKE A LOOK AT THAT SEAT.

SAY WE'VE MADE ALL OUR WONDERFUL LEGS-- A LOT TO ASSUME.

BUT WE'VE GOT... AGAIN, PINE TOP.

TELL ME WHAT THE FEATURES ARE HERE WITH THIS FINISHED SEAT.

AS I SAID BEFORE, THIS IS EASTERN WHITE PINE.

I'VE GOT THE LONG WOOD FIBERS, OR WHAT PEOPLE CALL THE GRAIN, RUNNING FRONT TO BACK.

AND DOWN HERE I'VE GOT THE LAYOUT FOR THE ANGLES OF THE LEGS.

THE LEGS ARE GOING TO BE BORED AND TAPERED.

TAPERED HOLES HERE.

AND I TURNED IT THERE TO THE UNDERSIDE.

THIS IS THE UPPER SIDE, AND SO SMOOTH.

THIS IS HOLLOWED OUT AND SCULPTED.

HOW DO YOU GET THE PATTERN FOR THIS?

HOW DO YOU KNOW WHAT'S GOING TO FIT THE KID?

I JUST GUESS, I GUESS.

YOU COULD TAKE YOUR KID AND PUT HIM IN A BUCKET OF SAND AND GET A MOLD.

AND YOU THROW THEM BACK TOWARDS THE-- I THROW THE DEPTH BACK TOWARDS THE BACK TO TRY TO KEEP YOU FROM SLIDING OUT.

THAT'S THE MAIN THING, AND FOR COMFORT.

ALL RIGHT.

WELL, LET'S GET YOU WORKING HERE.

I SEE YOU'VE GOT A PIECE...

I'VE GOT A PIECE RIGHT HERE THAT I'VE ALREADY HOLLOWED OUT.

AND THE TOOL THAT I STARTED OUT WITH THERE WAS THIS GUTTER ADZE HERE.

AH.

ALL RIGHT.

SO YOU'RE JUST SWINGING THAT AND CHOPPING OUT.

YOU'RE PAST THAT STAGE NOW.

RIGHT.

VERY FAST TOOL TO WORK WITH.

NOW, HERE IS THE SCORP, AND IT FOLLOWS THE ADZE, AND WE'LL BE WORKING WITH THIS IN JUST A MINUTE.

BUT I'M READY RIGHT NOW TO CUT OFF THE FRONT PART WITH THE DRAWKNIFE.

IT'S ALREADY DRAWN OUT AND READY TO GO.

SO I'LL JUST PUT IT IN THE VISE RIGHT HERE.

SO IT'S GOING TO BE THAT KIND OF WINGED DECLINE RIGHT THERE?

RIGHT.

GONNA CUT OFF THAT RIGHT THERE WITH THE DRAWKNIFE.

SO, LET ME GET MY KNIFE HERE, AND I'M CUTTING THE END GRAIN UP HERE, SO I'M GOING TO BE USING A SLICING CUT, AND THE DRAWKNIFE IS GOING TO BE SKEWED.

SO...OH, I SEE.

OK.

SO YOU'RE...HA HA HA.

JUST WHAT YOU SAID.

BECAUSE, AGAIN, THAT END GRAIN WOULD SPLINTER OFF.

SO KEEPING THE KNIFE AT AN ANGLE.

AND SLICING IT.

AND PULLING, SLIDING IT DOWN AS YOU DO IT.

GOOD LORD.

THAT'S JUST KIND OF THE SAME THING THAT WAS HAPPENING WITH THE LATHE THERE-- GETTING A SLICING CUT.

YEAH, SURE.

AND SO NOW I NEED ONE MORE CUT BACK OVER HERE ON THAT SIDE... UNBELIEVABLE.

AND THEN I'LL HAVE IT.

SO CLAMP THAT BACK UP.

THAT'S SO QUICK.

I KNOW YOUR STUDENTS SAY, "WELL, CURTIS, YOU DO EVERYTHING WITH A DRAWKNIFE."

RIGHT, CARVE THE TURKEY OR WHATEVER WITH IT.

YOU'VE GOT TO LEARN HOW TO TURN WITH YOUR DRAWKNIFE, AND THEN YOU'VE-- WELL, I'VE THOUGHT ABOUT GIVING IT A TRY FOR SOME THINGS.

YEAH.

ALL RIGHT.

AND THAT'S IT.

SO EASTERN WHITE PINE IS WHAT WE'VE GOT THERE FOR THE SEAT.

NOW, I SEE THAT DOES NEED SOME BLENDING THERE.

RIGHT.

NOW WE'VE GOT TO BLEND IT BACK IN.

AND SO THE FIRST TOOL THAT I'M GOING TO GO WITH HERE-- LET ME KNOCK IT DOWN WITH THESE HOLDFASTS.

ALL RIGHT.

IS THAT A GOOD POSITION?

YEAH.

THAT'LL BE OK.

YOUR HOLDFASTS HAVE THAT LEATHER ON THEM.

THAT'S KIND OF NICE.

AND SO I'LL GO BACK TO THE SCORP HERE AND...

I WAS GOING TO SAY, WHY USE THE SCORP?

BUT I CAN'T THINK OF ANY OTHER TOOL THAT WOULD DO IT AS WELL AND FAST.

RIGHT.

SO YOU'RE BLENDING THAT UP TO THE POMMEL THERE.

RIGHT.

I STOP AT THE POMMEL.

NOW YOU'RE GOING DOWN THE GRAIN A LITTLE BIT.

RIGHT.

NOW, I COULD CONTINUE ON WITH THIS TOOL, OR I COULD CHANGE BACK TO SOME OF MY SMALLER SHAVES.

THIS IS ONE RIGHT HERE.

IT'S CALLED A HEEL SHAVE.

IT'S A SHOEMAKER'S TOOL ACTUALLY, FOR HOLLOWING OUT HEELS.

IT LOOKS LIKE YOU'VE CUT THE HANDLES OFF, BECAUSE THEY USUALLY HAVE LONG HANDLES.

RIGHT.

I'VE CUT THE HANDLES OFF SO COLLECTORS DON'T WANT THE THING.

YOU'VE MADE BOTH HEELSHAVE COLLECTORS ANGRY AT YOU.

YEAH.

BOTH HEELSHAVE COLLECTORS.

BECAUSE THE HANDLES DROP DOWN, AND THEY GET IN THE WAY.

SO I'VE HAD TO CUT IT OFF SO I CAN USE IT... OH, IT WORKS REAL WELL.

YEAH.

IT'S A SWEET TOOL FOR THIS RIGHT HERE.

SEE?

AND ANOTHER ONE THAT I WOULD USE WOULD BE THIS TOOL RIGHT HERE.

IT'S A TRAVISHER.

SOME PEOPLE CALL IT THAT.

IT'S LIKE A CONVEX LENGTHWISE SPOKESHAVE.

AND THE OTHER WAY, TOO, I EXPECT.

RIGHT.

AND SO I CAN...

THIS HAS GOT TO BE THE BEST PART OF IT.

YOUR STUDENTS MUST REALLY LIKE THIS.

YEAH.

THESE TOOLS CAN FRUSTRATE THEM A LITTLE BIT.

IT'S HARD FOR THEM TO FIND THE CUTTING EDGE SOMETIMES.

SO THEY'LL RUN LIKE THIS OR LIKE THIS.

YEAH, YOU HAVE TO LOCATE THE CUTTING EDGE TO BE ABLE TO CUT WITH IT.

ONCE YOU GET IT, BOY, THIS IS SATISFYING WORK.

YEAH.

AND THEN THE NEXT SHAVE THAT I USE OUT HERE IS THIS SPOKESHAVE WITH A RADIUS SOLE FRONT TO BACK.

OK.

SO STRAIGHT IN THIS PLANE, BUT THIS WAY.

RIGHT.

SO I CAN GET-- I CAN'T GET INSIDE THE SEAT, BUT IT ENABLES ME TO GET OUT HERE AND SMOOTH ALL OF THIS DOWN.

THAT'S GREAT.

YOU'RE CHOOSING OUR ANGLE SO THAT YOU'RE ALWAYS GOING WITH THE GRAIN THERE.

YEAH, AND IF YOU HAVE TO GO CROSS-GRAIN, THEN YOU SKEW IT, AND YOU SEE THE PRETTY CUT THAT YOU CAN GET BY RUNNING CROSS-GRAIN ON THE PINE.

BUT, AGAIN, YOUR CARE TO SHARPENING GOES PARTICULARLY THROUGH THESE, BECAUSE THAT'S YOUR FINISHED SURFACE THERE.

YEAH, PRETTY MUCH.

IN SOME AREAS, THE EDGE TOOL IS MY FINISHED SURFACE.

AND SO, NOW WITH THAT DONE, I CAN BORE THIS HOLE RIGHT HERE.

ALL RIGHT.

NOW WE'RE ONTO-- THIS IS THE PIERCING NOW FOR THE LEGS TO GO INTO.

RIGHT, BECAUSE WE NEED TO BE ABLE TO STICK THE LEGS UP INTO THE SEAT.

SO WE NEED HOLES FOR THAT.

AND SO LET'S POSITION THIS...

I'D SAY RIGHT ABOUT LIKE THAT.

IS THIS GOING TO WORK RIGHT THERE?

BE GOOD.

AND I LIKE THAT.

THIS ONE'S NOT DOWN YET HERE.

OK.

NEED A...

THERE.

AND I NEED A MARK TO GO WITH SOMEWHERE.

SO LET'S PUT IT RIGHT THERE.

YOU JUST GO ON THE CENTERLINE?

WELL, I CAN SEE THE CENTERLINE.

IT'S RIGHT THERE.

SO I'M GOING TO LOOK BACK AT IT.

SO WE'LL PUT IT UP THERE SO YOU'LL KNOW WHERE THE CENTERLINE IS.

RIGHT.

OK?

AND NOW I NEED TO KNOW WHAT THIS ANGLE IS.

THE ANGLE THAT--BECAUSE WE'RE ON THE TOP OF THE SEAT, BUT THAT LEG HAS GOT TO SPLAY OUT.

THE LEGS RUN OUT THAT WAY, RIGHT.

AND THIS IS A 17-DEGREE ANGLE.

AND WE'VE GOT THE BEVEL SQUARE DOWN HERE SET UP... ALL RIGHT.

FOR THAT.

THAT WILL BE YOUR GUIDE FOR THE ANGLE OF THE AUGER.

MM-HMM.

AND WE'RE GOING TO BORE IT WITH... OH, LOOK AT THAT.

THIS BIT RIGHT THERE.

THAT'S WILD.

WHAT'S THAT CALLED, THAT KIND OF PATTERN?

IT'S A DEDGE BIT, OR A COOK'S PATENT BIT.

COOK'S PATENT.

AND IT DOESN'T HAVE THE...

HERE'S ONE.

HERE'S A REGULAR-- OR I SAY A REGULAR SPUR BIT THERE, A JENNINGS BIT.

RIGHT.

AUGER BIT, AND IT HAS THE NICKERS TO SCORE THE HOLE SO THE CUTTER THEN CAN CUT CLEAN.

BUT WE'RE NOT GOING TO USE THAT.

RIGHT.

WHEN YOU DRILL WITH ONE OF THESE AT AN ANGLE, YOU CAN PULL OUT A CHIP.

WHEREAS WITH THE COOKE'S PATENT BIT, YOU DON'T DO THAT BECAUSE THE CUT STARTS DOWN AROUND THE THREADS.

BUT IT'S ROUNDED, TOO.

IT'S LIKE THE TRADITIONAL SPOON BIT.

SO IT'S LIKE A COMBINATION BETWEEN A SPOON AUGER-- DON'T ANYBODY TRY AND GET IN TOUCH WITH YOU AND SAY, "WHERE CAN I GET THESE?"

BECAUSE THEY AIN'T MADE ANYMORE.

THAT'S THE THING-- YOU HAVE TO GET THOSE ANTIQUE.

AND I THINK THEY DIDN'T LAST VERY LONG, BECAUSE THEY MUST BE PRETTY FRAGILE.

I THINK THEY'RE HARD TO SHARPEN, TOO, I RECKON.

YEAH, THEY ARE HARD TO SHARPEN.

SO I'LL LINE UP RIGHT HERE WITH THAT AND GET THAT AT THE ANGLE THAT I WANT.

AND THEN I'LL LEAN BACK AT THAT AND BORE IT.

SO YOU WANT TO BE PLUMB OVER THAT MARK YOU MADE.

I SEE.

OK.

RIGHT.

YOU CAN SEE HOW NICE THE BIT ENTERS.

OH, YEAH.

IT REQUIRES LESS TORQUE THAN THE TRADITIONAL AUGER BIT, TOO.

AND IT CAN ALSO GO THROUGH THE OTHER SIDE WITHOUT BREAKING OUT.

IT WON'T SPLINTER?

RIGHT, UNLIKE AN AUGER BIT.

OH.

MAN, THERE'S LOTS TO LIKE ABOUT THAT.

SOMEBODY'S GOT TO START MAKING THOSE AGAIN.

RIGHT.

BUT NOW THIS IS A PARALLEL-- I MEAN, THIS IS JUST A ROUND HOLE.

BUT THE HOLES WE SEE, THEY'RE TAPERED, ARE THEY NOT?

RIGHT.

THEY'RE TAPERED.

SO I NEED TO FLIP THIS OVER.

AND WE'RE GOING TO TAPER IT FROM THE BOTTOM SIDE.

SO WE PULL THAT OUT LIKE THAT.

AND THAT OUGHT TO GIVE US ROOM RIGHT-- LET'S MOVE THAT ONE UP THERE.

THAT'LL GIVE US ROOM THERE.

AND WE NEED ONE MORE LINE HERE, WHICH IS THIS ONE RIGHT HERE.

YOU'RE DOING LOTS OF LINES, JUST UNEXPLAINED LINES HERE.

IS A GOOD WAY TO WORK ON THIS-- I ALWAYS TELL CHAIRMAKERS TO COPY ONE, LOOK AT A CHAIR AND COPY IT.

COPY THE ANGLES OFF OF IT.

THEY'RE NOT GOING TO GO INTO-- BECAUSE A LOT OF PEOPLE TEACHING WINDSOR CHAIRMAKING, YOURSELF INCLUDED, OF COURSE.

ALL RIGHT.

SO, NOW LET'S SEE.

I NEED THE TRY SQUARE SO I CAN LINE IT UP IN THIS PLANE.

AND THEN THE BEVEL SQUARE IS GOING TO HELP ME LINE IT UP IN THAT PLANE RIGHT THERE.

SO YOU'RE GOING TO COME IN FROM THIS SIDE.

SO I'M GOING TO COME IN FROM THIS SIDE.

LET'S SEE WHAT YOU GOT HERE.

THIS IS YOUR TAPER REAMER.

RIGHT.

IT'S A HOMEMADE TAPER REAMER.

IT'S BEEN MADE JUST FROM A SAW BLADE.

NOW, WHERE DID THIS COME FROM?

A FRIEND OF MINE, JOHN ALEXANDER, WAS THE ONE THAT RESEARCHED IT AND CAME UP WITH IT, AND IT WAS MADE REALLY FOR OUR WORK IN CENTRAL AMERICA, THE PROJECT YOU HAD3 MENTIONED BEFORE-- GREEN WOOD, THE SUSTAINABLE FORESTRY PROJECT.

AND WE NEEDED SOME SIMPLE TOOLS DOWN THERE, AND IT WORKS SO WELL THAT I'VE BEEN USING IT EVER SINCE.

IT'S GREAT.

AND THERE'S NOTHING FASTENING THE BLADE IN THERE.

THAT'S WONDERFUL.

SELF-CENTERING.

JUST LIKE ME-- SELF-CENTERED.

SO ANYWAY, I CAN JUST TAKE THIS HANDLE... UH-HUH.

AND... THAT'S WONDERFUL.

ALL RIGHT.

AND THOSE 2 BLADES SELF-CENTERED.

AND, AGAIN, IT'S 6 DEGREES ANGLE.

A 6-DEGREE ANGLE TOTAL.

ALL RIGHT.

AND THEN NOW I CAN SIGHT IT AND MAKE SURE THAT IT'S LINED UP WITH THIS LINE, THE TRY SQUARE, AND THE CENTER OF THIS, AND THEN IN THIS PLANE, OF COURSE, I CAN JUST PUT THE BEVEL SQUARE UP AGAINST IT, AND I CAN GET MY ANGLE RIGHT.

WORKS GREAT.

YEAH.

THEN YOU TAKE THE LEG THERE.

AND THE LEG HAS THE MATCHING MALE TAPER ON IT.

AND YOU DO THAT ON THE LATHE, OF COURSE.

YES.

AND JUST TWIST IT IN.

UNTIL YOU GET DOWN TO THE DEPTH THAT YOU WANT.

AND IT'S AS STRONG AS IT CAN BE.

ALL RIGHT.

NOW, OF COURSE, YOUR GREEN WOOD PROJECT-- YOU'RE TEACHING CHAIRMAKING TO FOLKS LIVING IN THE RAIN FOREST ESSENTIALLY OR THE DEEP FOREST.

VALUE-ADDED PRODUCTS.

TRYING TO MAKE THE FOREST TOO VALUABLE TO BURN.

THE PEOPLE HAVE TO BE ABLE TO MAKE A LIVING SOME WAY.

THAT'S GREAT.

ALL RIGHT.

WELL, THERE'S ONE LEG IN.

LET'S SEE.

I'VE GOT TO, OF COURSE, DO THAT 4 TIMES, JUST LIKE YOU HAD TO TURN 4 LEGS.

SO, ARE WE READY FOR THAT NOW?

YEAH.

WE'RE READY TO PUT IT TOGETHER.

ALL RIGHT.

LET'S GO AHEAD, THEN.

WE'VE GOT TO BORE SOME HOLES HERE AND ALL THAT.

SO LET'S TAKE THE... SET...

THE BLANK OUT THERE.

AND PULL THOSE OUT OF THE WAY.

ALL RIGHT.

I'M KIND OF LOST NOW.

NOW WAIT.

LET'S SEE.

NOW WE'VE GOT-- WE'RE GOING TO GET THIS BLANK OUT OF THE WAY RIGHT HERE.

RIGHT.

SO WE'RE AT THE ALL FOURS.

SUDDENLY MY MIND WAS OFF IN GUATEMALA MAKING CHAIRS WITH FOLKS.

COME BACK, ROY.

COME BACK.

I NEED TO GET BACK HERE.

ALL RIGHT.

DON WEBER WORKS WITH YOU ON THAT, TOO.

RIGHT.

DON, BRIAN BOGGS, AND SCOTT LANDIS ALL WORK WITH US.

THAT'S GREAT.

GREAT FOLKS THERE.

AND THERE YOU GO.

CHAIRMAKING CAN SAVE THE WORLD.

WELL, IT CAN MAYBE PLAY A SMALL ROLE... AT LEAST.

HA HA HA.

ALL RIGHT.

AND THEY'RE...I SEE.

OK, YOU'VE GOT THEM ALL NUMBERED HERE.

I'VE GOT THEM NUMBERED AND POSITIONED.

HERE YOU GO.

HERE'S NUMBER 4.

THERE'S NUMBER 4 HERE.

AND THEN WE'VE GOT AN "H" STRETCHER SYSTEM AROUND HERE SOMEWHERE.

RIGHT HERE.

SO THAT'S ALL DONE AT THESE DIFFERENT ANGLES HERE.

I SEE THESE SPLAY MORE ON THE FRONT OF THE CHAIR.

RIGHT.

THE FRONT HAS MORE SPLAY, AND THE REAR HAS MORE RAKE, WHICH IS THE OTHER ANGLE FROM THE SIDE.

SO IT DOESN'T TIP OVER BACKWARDS OR SIDE-TO-SIDE.

YES.

EXACTLY.

AND THEN THERE'S THE CENTER STRETCHER, RIGHT THERE, ASSEMBLY.

ALL RIGHT.

NOW, LOTS OF ANGLES IN HERE.

THIS IS THE "H" ASSEMBLY, THE STRETCHERS.

HOW TO GO ABOUT RECORDING THE ANGLES?

NOW, I SEE THE MARKS.

OF COURSE, WHEN YOU TURN YOUR LEGS, YOU LEAVE A LITTLE SCORE MARK.

SO I SEE WHERE THE SPINDLES ARE GOING TO GO IN-- I'M SORRY--THE STRETCHERS ARE GOING TO GO IN.

RIGHT.

SO I'VE SCORED THESE LINES WITH MY SKEW CHISEL, AND I KNOW EXACTLY WHERE THE STRETCHER IS GOING TO GO.

BUT NOW I NEED THE LENGTH SO I CAN PUT IT AT THE RIGHT... WHERE I'VE GOT THEM MARKED.

AND I CAN MEASURE THAT AND THEN ADD THE LENGTH OF THE TENON THERE.

YOU JUST DON'T WANT TO COME THROUGH THE OTHER SIDE.

DON'T WANT TO COME THROUGH, NO.

ALL RIGHT.

AND SO WE'VE GOT THE LENGTH.

THEN THE NEXT THAT I NEED IS THE ANGLE, WHICH IS A LITTLE TRICKIER TO MEASURE.

SO THAT'S WHY I USE THESE NICE BLUE RUBBER BANDS.

THAT CAN'T BE TOTALLY TRADITIONAL THERE, USING A RUBBER BAND THERE, BUT YOU COULD DO IT WITH A STRING OR WHATEVER?

YEAH, RIGHT.

OR JUST PUT A RULE ACROSS.

BUT, BOY, THAT DOES IT.

AND I'M SURE THERE'S LOTS OF OTHER WAYS THAT THEY GOT THE ANGLE, TOO, OTHER THAN EVEN PUTTING A STRING OR ANYTHING ACROSS IT.

YOU COULD JUST EYEBALL IT, I RECKON.

YEAH, YOU COULD JUST EYEBALL IT.

BUT THE STRING GIVES ME SOMETHING TO GO BY.

SO NOW I TAKE THE BEVEL SQUARE AND LINE IT UP DOWN THAT LEG, AND THEN MOVE IT TO WHERE...

IT LINES UP RIGHT ON THE RUBBER BAND.

SO NOW I TIGHTEN IT DOWN.

THAT ANGLE IS GOOD JUST FOR THAT LEG?

RIGHT.

ALL OF THEM MIGHT BE DIFFERENT, BUT USUALLY MY 2 REARS AND THE 2 FRONTS ARE THE SAME.

ALL RIGHT.

SO, NOW ASSUMING THIS ONE IS THE ONE YOU'RE READY TO BORE NOW.

LET'S SEE HOW YOU DO THAT NOW.

SO YOU'VE GOT THAT ANGLE RECORDED.

AND I GUESS YOU WANT TO USE-- DO IT IN THAT ONE.

THAT WILL BE A LITTLE SAFER.

SO LET'S MOVE THAT OUT OF THE WAY, AND THAT.

IT'S JUST THAT YOU RECORD IT, BUT THEN TO EXECUTE WHAT YOU'VE RECORDED AS THE PROPER ANGLE IS ALWAYS TOUGH, BECAUSE YOU'VE GOT TO LOOK DOWN AT YOUR BEVEL.

HOW DO YOU HOLD IT AND HOW DO YOU ACHIEVE THAT ANGLE?

YEAH.

SO FIRST OFF, WE NEED A MIRROR.

OH, I KNOW I DO.

YOU LIKE THAT?

OK.

I'M GOING TO HAVE TROUBLE GETTING THAT BACK, I THINK.

HA HA HA!

THIS IS GREAT.

AND THIS IS A WONDERFUL DEVICE, NOW.

IT GOES WAY BACK.

IT'S...WHAT?

YOU GOT A 3-POINT HOLDING SYSTEM, BUT WITH SOME WONDERFUL MODIFICATIONS, CURTIS.

THIS IS YOUR OWN INVENTION, TOO.

WELL, I GUESS YOU MIGHT BE ABLE TO SAY THAT, BUT IT'S EVOLVED FROM LOTS OF PEOPLE, SO WE'VE GOT A 3-PEG HOLDING SYSTEM THAT CAN HOLD ROUND OBJECTS, WITH JUST A WEDGE OVER HERE.

THEN I'VE COUPLED IT TOGETHER WITH THE "V" BLOCK, WHICH ALWAYS HOLD THIS LEVEL WITH THIS PART, WHICH IS WHERE MY BEVEL SQUARE IS GOING TO SIT.

ALL RIGHT.

SO SOMETHING TO HOLD IT.

YOU COULD HOLD IT IN A "V" BLOCK, WHICH PEOPLE WILL DO, AND DO THIS BUSINESS WITH THE BEVEL GAUGE.

NOW THIS IS GOING TO-- NOW I'VE GOT TO BE ABLE TO SEE IT.

NOW, I COULD LEAN OVER TO LOOK AT IT, LIKE I DID EARLIER, BUT I NEED A MORE ACCURATE HOLE WITH THIS ONE.

SO I, UM... DID YOU WANT TO LOCK IT HERE?

MY WEDGE WOULD BE NICE TO GET.

I SAW YOU HOLDING THIS THING.

YOU'VE GOT TO WEDGE THAT, I KNOW, AT SOME POINT.

SO WE'RE GOING TO DRIVE THE WEDGE IN THERE.

IN DIDEROT, IT SHOWS FRENCH CHAIRMAKERS.

AND I SEE YOU'VE ORIENTED THIS SO THE GROWTH RINGS ARE GOING IN THIS DIRECTION.

RIGHT.

SO YOU'RE GOING TO DRILL THROUGH THE GROWTH RINGS LIKE DOWN THROUGH THE FACE OF A DECK OF CARDS.

YEP.

SO I'M GOING TO FIND THE CENTER.

AND THEN I CAN MOVE THAT.

AND THAT'S LINED UP JUST RIGHT.

I CAN PUSH IT FORWARD.

NOW ALL I HAVE TO DO IS JUST GLANCE OVER, AND I CAN SEE IT.

SO IT'S REALLY JUST A WAY TO HELP YOU SEE YOURSELF IN THAT MIRROR THERE.

YEAH.

JUST LINE IT UP.

SO HERE I GO.

AND THAT'S IT.

LOOKING OVER AT THE MIRROR TELLS YOU THAT THAT AUGER IS ENTERING AT JUST THE RIGHT ANGLE.

SO, YEAH, VERY NICE.

HA HA!

SO IT'S ALL DONE WITH MIRRORS, AND WHEN WE GET TO THE STEAMING, WE COULD SAY IT'S DONE WITH SMOKE AND MIRRORS THERE.

WHAT A GREAT IDEA.

ALL RIGHT.

SO THIS IS IT.

THAT GETS YOU THE PROPER ANGLE, DONE WITH THE MIRROR.

I'M GOING TO GET THAT OUT OF THE WAY.

THAT'S ONE SCARY THING, THOUGH.

THAT'S WHY NOBODY DOES IT.

WHO WANTS TO HAVE A MIRROR IN THEIR SHOP?

SO NOW WE'VE GOT A ROUND MORTISE AND TENON JOINT HERE, WHICH IS ACTUALLY A FAIRLY POOR WAY TO PUT TOGETHER 2 PIECES OF WOOD, BECAUSE THE GLUE DOESN'T WORK REAL WELL.

BUT THIS HAS BEEN SUPER-DRIED, AND IT GOES INTO A MORTISE THAT'S A LITTLE BIT HIGHER MOISTURE CONTENT.

I SEE.

AND IT'S VERY TIGHT.

AND THEN ONCE IT GETS DOWN IN THERE, IT WILL SWELL INSIDE THERE.

AND SO...OH, MY GOSH.

ALL RIGHT.

AND SO NOW THAT'S READY.

YOU CAN KNOCK THAT OUT OF THE WEDGE THERE.

[HAMMERING] AH!

AND THERE IT IS.

SO YOU WORK WITH THAT "H" FRAME.

LET'S SEE.

I HAD THAT DOWN THERE.

AND START ASSEMBLING THESE PIECES INSIDE.

NOW, THAT SHOULD GET US TO THIS STAGE RIGHT HERE.

AM I RIGHT?

RIGHT.

ALL RIGHT.

SO YOU'VE GOT ALL THESE NOW GLUED.

YOU GLUE THESE AT THE TIME, AS WELL?

YEAH, THESE HAVE BEEN GLUED.

YEAH, I USE LIQUID-- I MEAN, I USE... DRY HIGH GLUE, HOT HIGH GLUE TO GLUE IT TOGETHER.

AND THESE ARE GLUED.

BUT AGAIN, MAKE SURE THE TENONS ARE DRY.

SO YOU PUT THEM BY THE FIRE?

YEAH, PUT THEM BY THE FIRE.

FIRE-DRIED, AS WE CALL IT.

AND THEN THE SEAT.

NOW, WE'VE GOT THE SEAT.

AGAIN, THE TAPERED HOLES, BUT YOU'VE SAWN SLOTS DOWN THROUGH THEM.

YEAH, FOR THE WEDGES.

SO WE'RE READY TO WIGGLE THIS INTO PLACE THERE.

YEAH.

I GOT IT.

ALL RIGHT.

ALL RIGHT.

SO THAT'S IT.

SO NOW GET GLUE AND WEDGES IN THERE, AND THIS IS THE UNDERCARRIAGE NOW.

SO WE'VE FINISHED THIS MUCH.

IF WE WERE JUST MAKING A STOOL, WE'D BE IN GOOD SHAPE HERE.

BUT WE'RE WORKING ON YOUR WONDERFUL WINDSOR CHAIR.

THIS IS WHAT WE'RE GOING TO HAVE TO DO NEXT TIME WHEN WE GET TOGETHER, CURTIS.

WE'RE GOING TO HAVE TO-- WHAT?--RIVE OUT THE PIECES?

SHAVE THEM DOWN?

WE'LL SPLIT OUT ALL OF THESE PARTS OUT OF THE LOG, AND THEN WE'LL DRAWKNIFE THEM TO SHAPE AND STEAM AND BEND.

STEAM AND BEND.

ALL RIGHT.

WELL, CURTIS BUCHANAN, THANK YOU SO MUCH.

WONDERFUL.

WE'VE GOT OUR WINDSOR HIGHCHAIR STARTED.

AND THANK YOU FOR JOINING ME.

GET US BACK HERE AGAIN, AND WE'LL FINISH HER UP NEXT TIME, RIGHT HERE IN "THE WOODWRIGHT'S SHOP."

WE'LL SEE YOU THEN.

BYE-BYE.

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 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.