Windsor Highchair With Curtis Buchanan, Pt.2

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."

[CARS HONKING] CAPTIONING MADE POSSIBLE BY U.S. DEPARTMENT OF EDUCATION HEY, HELLO AGAIN, AND WELCOME BACK TO "THE WOODWRIGHT'S SHOP."

I'M ROY UNDERHILL, AND I'M SO GLAD YOU COULD BE WITH ME AGAIN TODAY, BECAUSE OUR GOOD FRIEND CURTIS BUCHANAN IS HERE AGAIN.

HEY, CURTIS.

HEY, ROY.

HEY, WONDERFUL TO SEE YOU HERE.

AND THIS IS SUCH A WONDERFUL CHAIR HERE.

THIS IS A-- WHAT IS IT NOW?

IT'S A COMB-BACK WINDSOR CHAIR.

COMB IS RIGHT UP HERE.

IT GOES UP THERE WHERE THE HAIR WOULD BE.

YEP.

THERE'S THE COMB, AND THERE'S THE SPINDLES ON DOWN.

THE SPINDLES HERE.

WE HAVE A BACK HERE THAT'S STEAM-BENT.

AND THAT'S WHAT WE'RE GONNA DO THIS TIME.

WE'RE GONNA DO ALL THIS UPPER CARRIAGE PART.

WE'LL PUT OUT SOME SPINDLES AND BEND THE BACK.

AND LAST TIME WE GOT TOGETHER, WE DID THE SEAT AND THE LEGS AND SO FORTH.

THE UNDERCARRIAGE.

THAT'S THE UNDERCARRIAGE.

ALL RIGHT, 'CAUSE WE GOT THIS MUCH DONE, WE GOTTA STILL--NOW WE'RE GONNA DO THE UPPER PART, ARMS AND BENDING AND SPINDLES.

ALL RIGHT.

WONDERFUL.

AND THIS ONE HAS THE FINISH ON IT.

WE'LL MAYBE GET TO TALK A LITTLE BIT ABOUT THAT, BUT LET'S START WITH THE WOOD.

LET'S START WITH THE TREE.

ALL RIGHT.

I SEE YOUR SHAVEN HORSE IS ALREADY OVER HERE, AND YOU GOT YOUR WOOD.

I GOT THIS PIECE OF CHESTNUT OAK RIGHT HERE.

AND THIS IS THE TOP OF A WHITE OAK, I BELIEVE.

THAT'S IT-- IT'S DIFFERENT.

YEAH, IT'S A LITTLE BIT DIFFERENT, YEAH.

THAN THE REGULAR WHITE OAK.

AND WE GOT A FROE HERE THAT WE'RE GONNA SPLIT IT WITH.

AND HIT IT WITH OUR WOODEN DOGWOOD FROE CLUB.

DOGWOOD.

ALL RIGHT.

WELL, IT SPLITS STRAIGHT.

I GOTTA SAY THAT.

IT SPLITS PRETTY GOOD.

SO WE'LL SEE IF WE CAN GET-- LET'S SPLIT IT THIS WAY RIGHT NOW.

SHOULD I TURN IT THAT WAY?

YEAH.

SO YOU'RE ALWAYS SPLITTING IN THE MIDDLE, I SEE.

YEAH.

THAT'S THE RULE.

YOU CAN BEND IT A LITTLE BIT, BUT... OH, YEAH.

ALL RIGHT, SO WHEN YOU'RE WORKING DOWN HERE, YOU'RE ACTUALLY CAPTURING THE STRENGHT OF THE WOOD BY THAT SPLIT I THINK.

RIGHT.

YOU'RE TRYING TO MAINTAIN THOSE LONG WOOD FIBERS ALL THE WAY DOWN INTO THE CHAIR, 'CAUSE THAT IS THE STRENGTH OF THE PIECE.

NOW, YOU'RE ON THE DIVIDE THERE ON THIS PIECE BETWEEN THE SAP AND THE HEART WOOD.

IS THAT ALL RIGHT?

YEAH, IT IS FINE.

DOESN'T--A LOT OF PEOPLE DON'T LIKE TO DO IT.

I'VE NEVER SEEN ANY DIFFERENCE IN IT MYSELF.

REALLY?

ALL RIGHT.

SO, YOU GOT A BIG OLD PIECE THERE, AND THAT'S GONNA GO DOWN TO A SPINDLE.

RIGHT.

I COULD SPLIT IT DOWN A LITTLE BIT FURTHER, BUT...

BUT THEN YOU HAVE THE CHANCE OF IT RUNNING OUT WITH THAT RIDING BRAKE.

I KNOW THAT'S GONNA MAKE IT RISKY.

SO I'M GONNA SMOOTH ONE SIDE, BUT NOT ONLY AM I SMOOTHING IT, BUT I'M ALSO FOLLOWING THE LONG WOOD FIBERS.

YOU'RE SEEKING OUT THAT GRAIN.

NOW, YOU'RE ON THE RADIAL-- THE RADIAL PLANE RIGHT NOW.

RADIAL PLANE RIGHT NOW.

RIGHT.

SO NOW I'M ALL IN THE SAME LEVEL.

THE DRAWING KNIFE'S TELLING ME THAT.

THE DRAWING KNIFE TELLING YOU.

AND YOU CAN SEE THE RAISE GET A LITTLE LONGER THERE.

I CAN SEE.

RIGHT.

YEAH, YOU DO-- YOU CAN LOOK AT THE RAISE AND SEE THAT.

SO LET'S TURN BACK OVER HERE TO THIS TRANSVERSED SIDE, AND OVER HERE, YOU'RE KIND OF COLOR-CODED.

GOSH, YEAH.

'CAUSE EACH GROWTH RING, EACH ANNUAL RING OF THE TREE-- UH-HUH.

SO RIGHT HERE YOU CAN SEE THE WAY THAT IT'S STEPPING DOWN.

YEAH.

SO IT'S BUILT UP RIGHT HERE, AND I NEED TO GET RID OF SOME OF THAT EXCESS.

LOOKS LIKE A CONTOUR MAP.

YOU'RE ON A CONTOUR.

YOU WANT TO HAVE IT ALL FLAT THERE.

UH-HUH.

SO GET DOWN BETWEEN...

SO I'M DOWN TO LEVEL RIGHT THERE, BUT I WENT DOWN A LITTLE BIT FURTHER THERE.

SO LET ME TURN IT AROUND AND TAKE THAT OFF.

OK. NOW IT'S ALL ABOUT THE SAME COLOR.

RIGHT.

I'M IN ONE PLANE HERE.

SO NOW I'M GONNA DIMENSION IT, AND BEFORE I DO THAT, I'LL MARK IT WITH MARKING GAUGE.

THIS WILL BE THE LARGEST DIAMETER THAT'S FOUND IN THE SPINDLE.

ON THE SPINDLE.

ALL RIGHT.

'CAUSE WE'RE MAKING THIS PART.

YOU'LL SEE.

WORKING ON THIS PART RIGHT HERE-- ONE OF THESE SPINDLES.

RIGHT.

SPINDLE RIGHT THERE.

AND SO THAT'S GONNA-- THAT GAUGE IS SET TO THIS DIMENSION RIGHT HERE.

EXACTLY.

IT'S FAT THERE, AND THEN TAPERED DOWN.

ALL RIGHT.

I'LL JUST MAKE SURE.

SEE WHAT'S GOING ON HERE.

ALL RIGHT.

AND I'M USING A-- A MARKING GAUGE LIKE THAT INSTEAD OF A PENCIL.

OH, I CAN SEE-- I SEE THE LITTLE HAIRY THINGS RIGHT THERE.

YEAH.

AND THEN WHEN YOU TAKE THAT OFF-- I DON'T HAVE TO LOOK OVER TO THE SIDE TO SEE WHEN I'M THERE.

THAT'S GREAT.

I LIKE THAT.

NOW THIS IS WHAT-- YOU LEARNED YOUR WINDSOR CHAIR MAKING FROM ONE OF THE GREAT CHAIR-MAKERS OF THIS LAND, I THINK.

WELL, FROM DAVE SAWYER IN EAST CALAIS, VERMONT.

HE TAUGHT ME ABOUT 25 YEARS AGO.

HE'S A VERMONTER, AND YOU'RE FROM TENNESSEE, SO HE'S KIND OF A NORTH-- AND I MEAN THIS IN THE BEST SENSE-- THE YANKEE EQUIVALENT OF SOUTHERN WOODWORKER.

THE CIVIL WAR, MAYBE.

MAYBE THAT'S WHAT WE DID.

THAT'S GREAT.

THAT'S IT.

THANK GOODNESS.

Y'ALL GET ALONG WELL.

HE'S A WONDERFUL FELLA THERE.

YEAH.

HE WAS A VERY GIVING PERSON.

AND QUITE A SCHOLAR, TOO, OF WOODCRAFT.

LET'S SEE WHAT YOU'RE DOING HERE NOW, 'CAUSE THIS IS WHERE THE WOOD IS GONNA TEACH US.

OK, SO NOW I'M DOWN TO THE SQUARE THAT I WANT.

UH-HUH.

SO THAT'S ALL THAT LARGEST DIAMETER.

RIGHT.

SO NOW THE NEXT THING I'M GONNA DO IS FORM THE TENON THAT GOES INTO THE C. OK, SO THE BOTTOM END.

THE BOTTOM END.

YES, EXACTLY.

SO I'M GONNA START LIKE THAT.

YOU DON'T TRY AND ROUND IT OFF RIGHT AT THE START.

YOU GO SQUARE.

YEAH.

I LIKE TO LEAVE REFERENCE POINTS SO EVERYTHING IS MORE CONSISTENT.

OK.

I GO ACROSS, SO--SO I'VE GOT THAT SHAPED.

UH-HUH.

AND NOW I'M GONNA GO WITH THE TAPER.

UH-HUH.

IT COMES UP TOWARDS THE TOP.

AND I SEE YOU'RE WORKING WITH YOUR JAW KNIFE.

CAN YOU STOP FOR A SECOND?

YOU'RE WORKING WITH IT WITH THE BEVEL DOWN.

I'M NOT GONNA TOUCH IT.

THIS IS THE FLAT SIDE UP AND THE BEVEL DOWN, AND I GUESS EACH KNIFE IS DIFFERENT?

RIGHT.

EACH KNIFE IS DIFFERENT, AND THIS ONE LENDS ITSELF BETTER TO BE USED WITH THE BEVEL DOWN BECAUSE THE BLADE IS IN LINE WITH THE HANDLES.

SO THE FLAT OF THE BLADE GOES RIGHT THROUGH-- RIGHT.

IT'S IN LINE WITH THE HANDLES.

AND I CHOOSE IT FOR THIS SPINDLE-MAKING BECAUSE I NEED THE CONTROLLING-- OH, YOU NEED TO GO INpAND COME .

'CAUSE I HAVE KNIVES THAT ARE SHARPENED WITH THE BEVEL UP, AND THEREFORE DOING LONGER, STRAIGHTER PIECES.

I'M GONNA KNOCK YOUR PIVOT BOLT IN.

THERE YOU GO.

THAT CAN COME OUT.

YEAH, AND YOU GET STABBED IN THE STOMACH WITH A SPINDLE.

THERE YOU GO.

THAT'S WONDERFUL.

NOW, IT IS AGAIN DEAD GREEN WOOD NOW.

THIS IS GREEN AS A GOURD RIGHT NOW.

SO WE'RE GONNA SHAPE IT, AND THEN AFTER IT-- WE'RE SHAPING IT GREEN BECAUSE IT'S SOFT.

IT'S EASY TO CUT, AS YOU CAN SEE.

VERY EASY.

A LOT OF FUN.

A LOT OF FUN TO CUT IT.

WHEN I GET IT SHAPED...

I'M DOING OCTAGONAL RIGHT NOW.

SO YOU'VE GOT SQUARE, OCTAGONAL, AND... DO YOU STOP WHEN IT GETS TO THE OCTAGON BEFORE YOU GO TO THE ROUND, OR...?

I STOP AND I DRY IT.

THAT'S WHEN I'LL DRY THIS PIECE.

THAT'S WHAT I WAS THINKING.

WHERE DOES THAT DRYING STAGE COME IN?

IT'S THAT ADVANTAGE OF THE GREEN WOOD, YOU KNOW, HAVING IT WORK EASY.

IT ALSO DOESN'T HOLD TOGETHER AS WELL, SO YOU CAN'T GET AS GOOD A FINISH ON IT.

RIGHT.

UH-HUH.

SO I'M GONNA BE DRYING THIS AFTER THIS POINT RIGHT HERE.

SO NOW WE'VE GOT-- UM, YEAH.

A SPINDLE IN OCTAGONAL.

YEAH, ALL RIGHT.

THAT'S READY TO GO BY THE STOVE OR SOMETHING LIKE THAT.

RIGHT.

NOW WE'LL PULL THIS ONE OUT.

OH, ALL RIGHT.

AND THIS IS--OH, I SEE--BOY, YOU SEE.

IT JUST WEIGHS HALF AS MUCH AS THIS ONE DOES, TOO.

SO THIS ONE'S DRIED OUT NOW?

YOU HAVE THIS DRY BY THE FIRE?

RIGHT.

SO NOW I CAN DO THE FINAL SHAPING ON IT, AND I USE A SPOKE SHAVE FOR THAT SO IT HAS A MORE CONTROLLED CUT.

I SEE.

IT'S KIND OF LIKE A PLANER.

YOU CAN EVEN HEAR THE DIFFERENCE... YEAH.

WITH IT.

AND THE SPOKE SHAVE WOULDN'T RESPOND-- THE GREEN WOOD WOULDN'T RESPOND AS WELL TO THE SPOKE SHAVE.

WELL, NOT AS WELL, BUT IT'S OK TO USE THE SPOKE SHAVE ON GREEN WOOK.

IT JUST GETS A BETTER FINISH ON DRY WOOD, SO THAT'S WHY I GO AHEAD AND DRY IT BEFORE I USE THE SPOKE SHAVE.

YES.

AND THIS IS STRONG-- THIS WHOLE THING, IT'S LIKE A LONG PROCESS TO MAKE A THIN PIECE OF WOOD, BUT YOU HOLD THAT IN THERE--GRAB DOWN ON IT.

THAT IS--THAT IS STRONG.

RIGHT.

BECAUSE WE HAVE FOLLOWED THE WOOD FIBERS.

IN ORDER TO BREAK IT, IT WOULD HAVE TO BREAK STRAIGHT ACROSS.

OK.

INSTEAD OF SPLIT ALONG THE GRAIN-- RIGHT, ALONG DIAGONAL THERE LIKE WE SPLIT IT THE FIRST TIME.

NOW I GUESS THESE PIECES HERE-- THESE WOULD BE GOOD FOR YOUR OTHER PARTS, TOO?

SURE.

OK, SO YOU COULD GET OUT YOUR...

I COULD GET THE COMB OUT OF THAT.

AND THE PART THAT'S A LITTLE BIT LONGER, I WOULD GET OUT A BACK SUCH AS THIS.

THIS WOULD BE THE ARM RAIL.

OK, AND AGAIN, JUST SPLIT THAT OUT, AND THEN SHAVE IT DOWN.

YOU CAN SEE THE STRAIGHT WOOD FIBERS THAT'S IN IT.

THE DRAW KNIFE HAS FOLLOWED THOSE.

PERFECTLY STRAIGHT.

AND OF COURSE THIS WE'RE GONNA BEND.

RIGHT.

THIS IS WHAT WE HAVE IN THE STEAM BOX.

OH, ALL RIGHT.

AND THAT'S VERY IMPORTANT THERE TO HAVE THE GRAIN INTEGRAL IN THAT PIECE BECAUSE OF THE STRESS OF THE BENDING.

RIGHT.

WELL, LET ME SEE.

SHALL I TAKE A PEEK AT THIS PIECE UP HERE?

SO WE'VE GOT A STEAM BOX.

THE STOVE IS GOING RIGHT GOOD.

AND I'LL JUST PEEK IN AND SEE--ALL RIGHT.

PLENTY OF STEAM.

IT'S HOT.

DO YOU WANT ME TO GIVE IT A GO?

YEAH, BUT LET'S FIRST JUST SHOW WHAT WE'RE GONNA BEND IT AROUND OVER HERE.

ALL RIGHTY.

YEAH.

WE'VE GOT A BENDING FORM RIGHT HERE, AND IT'S JUST A 3-PEG HOLDING SYSTEM WHERE WE'RE GONNA PUT IN THE PEGS, DRIVE A WEDGE, AND BEND IT AROUND.

BUT THIS PIECE IS SO THICK FOR ITS LENGTH THAT WE NEED A LITTLE MORE HELP.

UH-HUH.

SO THAT'S WHERE I BEND WITH A STRAP.

WE BEND IT WITH THIS STRAP RIGHT HERE, AND THIS EXTRA HANDLE IS GONNA GIVE ME THE LEVERAGE THAT I'M GONNA NEED.

SO WE'RE GONNA POP THAT PIECE IN LIKE THAT...

RIGHT.

AND LOCK IN IT, AND BEND IT AROUND.

AND JUST SO WE KNOW WHAT WE'RE DOING.

THIS IS GONNA-- THIS PIECE IS GONNA BE THIS PIECE.

RIGHT, EVENTUALLY.

IT'S GONNA BE BENT RIGHT LIKE THAT.

BENT AROUND AND HAVE THE CARVING AND THE HOLES PUT IN IT, BUT RIGHT NOW, IT'S A HOT STICK OF WOOD, SO I GUESS WE'RE READY TO TRY IT.

SO IF YOU GO PULL THAT OUT, I'LL BE READY FOR YOU.

ALL RIGHT.

NOW, DO I HAVE TO HURRY WHEN I GET THIS THING OUT OF THERE?

WELL, IT'S NOT TOO MUCH OF A HURRY.

JUST 30, 45 SECONDS OR SO, BUT THAT'S PLENTY OF TIME.

PLENTY OF TIME IF YOU GOT EVERYTHING READY.

YOU DON'T WANT TO BE LOOKING FOR YOUR HAMMER OR YOUR FORM OR ANYTHING.

WELL, THERE IT IS, AND IT'S HOT.

I THINK IT'S HOT.

I HOPE IT'S HOT.

OK, NOW WE'VE GOT A LINE THAT'S GONNA BE DOWN TOWARDS YOU RIGHT THERE.

ALL RIGHT.

AND THAT GOES FLUSH UP TO THIS RIGHT SIDE.

OK, AND YOU GET THE C-CLAMP THERE.

ALL RIGHT.

AND HOW LONG, AGAIN, YOU HAVE TO STEAM SOMETHING THIS THICK?

THIS--OH, PROBABLY 30 MINUTES FOR THIS ONE IF IT'S GREEN.

AND WE'RE UP--WE'RE RIGHT-- ARE WE ALIGNED RIGHT?

UH-HUH.

ARE YOU READY?

YEAH.

I'M READY.

LET'S SEE IF WE CAN PULL IT AROUND.

HOLY MOLY.

LOOK AT THAT.

YOU GOTTA JUST BRING IT-- THAT STRAP KEEPS IT FROM BUCKLING ON THE BACK, TOO.

RIGHT.

ALL RIGHT, NOW, WHAT DO IT DO?

SO THERE WE GO.

NOW WE WANT TO PEG AND WEDGE IT.

SO I CAN LET IT GO.

OH.

AND I CAN PULL THIS BACK AROUND.

YOU CAN WEDGE IT, TOP DEAD-CENTER THERE.

ONCE IT'S BEEN BENT, IT'S EASY TO BEND AGAIN, OR EASIER TO BEND AGAIN.

AND TAKE THAT HAMMER AND DRIVE THAT IN A LITTLE BIT THERE.

ALL RIGHT.

OK. THAT'LL DO.

NOW, OVER HERE.

HURRY UP.

YOU GOT IT?

YEAH.

I STILL CAN'T GET IT.

LET ME PULL WITH YOU.

OK, READY.

ALL RIGHT.

THERE WE GO.

OH, I'M NOT ALL THE WAY THROUGH.

YOU GET ONE SHOT.

PUSH IT BACK OUT.

OK, YOU GOT IT.

OK.

THIS WOOD IS STRONG!

YEAH.

THAT'S WHY YOU NEED THAT STRAP TO BEND IT WITH.

HERE WE GO.

I CAN GET THAT.

HOLY COW.

NOW, YOU'RE GONNA LET THIS END GO OVER HERE?

I'LL TELL YOU WHAT.

LET'S LEAVE IT IN THE CLAMP RIGHT THERE.

I FEEL A LITTLE MORE SECURE.

OK. WE'LL LEAVE IT IN THE CLAMP.

WE CAN DO THAT, BUT YOU CAN TAKE THIS OFF.

BUT DO YOU DO THAT THING OF YOU BEND-- I SAW YOU LET IT GO A LITTLE BIT, AND THEN BEND IT AGAIN.

RIGHT.

IT'S ALREADY BEEN BENT, SO IT'LL JUST TAKE RIGHT BACK, AND YOU CAN SEE HOW GOOD THE BEND WAS.

IT'S VERY GOOD.

BEAUTIFUL.

BUT YOU COULD ALSO SEE FROM THE POWER THAT IT TOOK TO EVEN IT BRING IT BACK IN AFTER IT HAD BEEN BENT.

THAT'S WHY WE HAVE TO USE THAT STRAP.

GOOD HEAVENS.

THE FIRST TIME WOULD BE EXTREMELY DIFFICULT TO PULL IT AROUND BY YOURSELF.

ALL RIGHT.

A BIG, OLD, THICK PIECE OF WOOD NOW.

BUT THAT--THE HEAT HAS PLASTICIZED THE FIBERS.

NOW WHAT?

NOW HOW LONG HAS THAT GOT TO STAY THERE TO...?

UNTIL IT DRIES, WHICH DEPENDS ON WHERE YOU PUT IT AND WHAT KIND OF YEAR IT IS.

SO IF YOU PUT IT NEAR YOUR STOVE, IT MIGHT BE A WEEK OR 2 IT WOULD BE READY.

REALLY?

OR YOU COULD SPEED IT UP.

AND IT'LL HOLD IT'S SHAPE ONCE IT COMES OUT?

ALL RIGHT.

WELL, IN FACT, THIS LOOKS LIKE THE NEXT STAGE.

ONCE IT COMES OFF OF THERE, YOU'VE DONE A FEW THINGS TO IT.

WHAT'S HAPPENING HERE?

FIRST THING THAT I'VE DONE IS I'VE CUT THIS EXCESS OUT RIGHT HERE.

AND WE HAD TO DO THAT AFTER, 'CAUSE IF WE'D DONE IT BEFORE, THE BEND WOULDN'T BEND EVEN.

THIS IS TOO WEAK.

SO IT MIGHT TWIST THERE OR SOMETHING.

THAT'S NOT LIKE THERE'S 2 PIECES THERE.

THAT'S THE THICKNESS, AND IT GETS CUT AWAY.

AND THEN WE HAVE TO HAVE MORE MEAT UP HERE FOR THE HAND HOLD.

SO I'VE GLUED AN EXTRA PIECE ON RIGHT THERE.

AND THAT'S THE TRADITIONAL WAY YOU DO IT.

YOU TAKE SOME AWAY AND YOU ADD SOME ON.

RIGHT.

UH-HUH.

AND EVENTUALLY WE'LL BE ADDING A LITTLE BIT MORE HERE FOR THE KNUCKLE THAT YOU SEE ON THIS PIECE RIGHT THERE.

OK, A KNUCKLE THAT HANGS DOWN A LITTLE BIT RIGHT IN THERE.

RIGHT.

ALL RIGHT.

OK. AND I'VE ALREADY BORED THE HOLES FOR THE ARM SUPPORTS.

ALL RIGHT.

WELL, WE'VE GOT A PIECE HERE.

LET'S SEE.

NOW, THIS IS WHAT WE DID LAST TIME WE GOT TOGETHER-- WAS WORK ON THIS UNDERCARRIAGE.

SEE IF I CAN SET THAT.

NOW, HERE'S SOME OF THIS, AND THIS IS GREAT TO GET TO SEE THESE AGAIN, THESE POSTS.

LET'S SEE WHICH ONE GOES WHERE.

NOW, THESE ARE TAPERED, THESE ARE TAPERED HOLES JUST LIKE WE DID WITH THE LEGS.

EXACTLY.

EXACTLY.

TWIST THOSE THINGS IN.

YOU GOT A MARK RIGHT OVER HERE YOU CAN LINE IT UP WITH.

I SEE.

NOW, THAT'S IT.

BOY, THEY REALLY DO LOCK.

NOW WE PUT THE HAND HOLD ON THERE LIKE THAT.

UH-HUH.

OH, AND IT JUST SITS UP.

NOW I'M READY TO DRILL A HOLE BACK HERE.

NEED A LITTLE SUPPORT.

OH, ALL RIGHT.

WE'LL SET THIS DOWN ON THE FLOOR THEN, I GUESS, FOR THAT, 'CAUSE OTHERWISE YOU HAVE TO BE PRETTY TALL TO WORK ON THE BENCH.

SIT IT ON THE FLOOR.

NOW I'LL DRILL THIS HOLE RIGHT HERE.

OK.

SO HERE WE GOT-- THIS IS IT.

SO YOU REALLY HAVE IT AT THIS STAGE RIGHT NOW FOR THE BORING.

UH-HUH.

ALL RIGHT.

SO YOU'VE ALREADY PACED THESE OFF NOW SO YOU KNOW WHERE THE-- YOU KNOW WHAT I'M GONNA DO IS I'M GONNA PUT A SUPPORT UNDERNEATH THAT TO TRY TO BACK IT UP SO I CAN DRILL INTO IT AND NOT BREAK THROUGH ON THE OTHER SIDE.

AH, OK, SO IT WON'T SPLINTER THE OAK DOWN THERE.

NOW SEE HOW THIS LITTLE SUPPORT PIECE WORKS THERE.

THAT'S GREAT.

SO NOW I'M GONNA JUST SIGHT DOWN AT THIS HOLE, WHICH IS WHERE THAT SPINDLE'S GONNA COME OUT OF.

I SEE.

I GOT YOU.

SO YOU JUST REALLY ARE EYEBALLING AND GUNSIGHTING-- JUST SAT RIGHT DOWN LIKE THAT.

I GOT IT.

AND SEE THAT YOU'RE AIMED RIGHT AT IT.

GOD, THIS HAS GOTTA BE JUST-- BUT I SEE IT DOES MAKE SENSE NOW HOW YOU'RE DOING THIS.

BECAUSE THEY LOOK SO FRAGILE, BUT YOU BORE THE HOLES FIRST BEFORE YOU DO THIS SHAVING AWAY.

WHEN YOU SEE THE FINISHED PIECE, IT'S MUCH THINNER.

RIGHT.

IT'S EASIER TO BORE THE HOLE-- LET'S SEE IF I GOT THAT.

IS THAT ALL THE WAY THROUGH?

YEAH.

IT WENT ALL THE WAY THROUGH.

YEAH.

IT'S EASIER TO BORE THE HOLES WHILE IT'S FLAT THAN IT IS WHILE IT'S ROUND.

YEAH, AND SEE HERE.

THIS IS THE FINISHED PIECE HERE.

I SEE IT--BOY, THAT IS SOME SCANT WOOD RIGHT THERE.

YOU THINK, "HOW WOULD YOU DRILL THROUGH THAT?"

WELL, OF COURSE YOU DRILL FIRST AND THEN SHAVE UP TO IT.

AND ALSO HARDER FOR YOUR BIT TO CUT A CLEANER HOLE.

RIGHT.

BECAUSE THE CUTTER WILL START HITTING BEFORE THE SCORE IS HIT, BEFORE THE KNICK IS HIT SO IT CAN PULL OUT A CHIP OVER HERE ON THIS SIDE.

WELL, NOW THAT'S JUST THE TOP HOLE.

YOU GOT ONE AT THE BOTTOM?

RIGHT.

YOU GOTTA DRILL ONE RIGHT DOWN THERE.

SO WE'LL TAKE OUR BIT OUT OF THERE.

ALL RIGHT.

AND WE'RE GONNA THREAD THIS ONE RIGHT UP THROUGH HERE, AND SET IT RIGHT ON... AH, OK.

SO THE AUGER IS TAKING THE POSITION THAT THE SPINDLE WILL TAKE.

EXACTLY.

SO IT'S GONNA BE STRAIGHT.

ALL RIGHT.

GOT YOU.

I LIKE YOUR BRACE THERE.

IT'S A LITTLE SPOFFORD BRACE THERE WITH JUST THE SINGLE-SET SCREW.

YOU LIKE THAT?

OH, YEAH.

IT'S MY FAVORITE KIND.

AND THAT'S A LOT QUICKER TO WORK WITH THERE, TOO, I THINK.

AND YOU GOTTA BE COUNTING YOUR TURNS OR SOMETHING.

YEAH.

WITH AN AUGER BIT, ONE OF THE ADVANTAGES IS FOR DEPTH, ALL YOU HAVE TO DO IS COUNT YOUR TURNS.

AH.

SO I'M COUNTING 22 TURNS FOR THAT.

THAT GETS YOU HOW DEEP INTO THE SEAT?

RIGHT AT ABOUT 15/16.

THERE YOU GO.

THERE'S THE HOLE AT THE BOTTOM.

THE HOLE AT THE TOP.

WHOO.

ALL RIGHT.

NOW YOU'VE DONE ENOUGH OF THESE THAT THIS IS NOT NERVE-WRACKING FOR YOU, BUT IT WOULD DRIVE ME CRAZY.

ALL RIGHT.

NEXT STEP.

NOW WE HAVE TO TAPER THE BOTTOM OF THIS HOLE BECAUSE I LIKE FOR THE ARM RAIL TO SIT ON THE TAPERED SPINDLES.

AND SO LET'S TAKE THAT OUT.

AND I'M GONNA LOCK IT IN TO A VICE HERE.

UH-HUH.

SO WE'RE LOOKING AT-- I GOT THE TOP ON THIS SIDE HERE.

RIGHT.

AND I TAPER IT USING SOMETHING... RATHER UNCONVENTIONAL, WHICH IS A RAT-TAIL FILE.

YEAH, AND IS THIS AGAIN... WHERE DID YOU PICK THIS UP?

OK, THIS WAS A TRICK DAVE SAWYER TAUGHT ME.

AND IT GIVES A NICE SUBTLE TAPER.

AND THE SPOFFORD LETS IT MOUNT INSIDE THE SPOFFORD.

SO TO SEAT IT, I TAKE IT IN CLOCKWISE, AND IT CORKSCREWS ITSELF IN.

IT WOULD SPLIT IT IF YOU KEPT GOING.

RIGHT, SO AS SOON AS YOU FEEL IT SEAT, THEN YOU GO BACK IN A COUNTERCLOCKWISE POSITION.

OH, LOOK AT THAT.

I CAN SEE THE FINE FINE SHAVINGS COMING OUT THIS TOP END HERE.

AND THAT MIGHT DO IT RIGHT THERE.

SO WE'LL TAKE THIS SPINDLE-- THE RAT-TAIL FILE... AND WE'LL RUN IT RIGHT UP THROUGH THERE.

AND SO YOU DO IT UNTIL THAT PENCIL LINE GOES-- TILL I GET IT UP TO THE PENCIL LINE RIGHT THERE.

AND THAT GOES FLUSH.

SO YOU GOT YOUR BOLD DOWN BELOW THE ARM RAIL FITTED ON.

YOU SEE THE TIGHT FIT THAT IT GIVES US UP THERE.

GIVES YOU A TIGHT FIT TOP AND BOTTOM.

YEAH.

ALL RIGHT.

SO, WE KEEP DOING THAT.

LOTS OF THESE ALL THE WAY ACROSS.

AND THIS IS ALL BORED AND TAPERED, THIS ONE RIGHT HERE?

YEAH, THIS ONE'S READY TO GO ON.

ALL RIGHT.

WELL, I GUESS THAT'S IT.

WE KEEP UP THAT SAME PROCESS FOR ALL THE SPINDLES.

RIGHT.

LET'S PUT IT TOGETHER HERE.

I'LL MOVE THIS ONE OUT OF THE WAY.

ALL RIGHTY.

AND WE'VE GOT ONE BACK HERE.

ALL RIGHT.

OOH, WITH ALMOST ALL THE SPINDLES.

THIS LOOKS LIKE IT'S MISSING ONE.

IS IS MISSING SPINDLE NUMBER 9, SO... LET'S LINE THAT UP.

YEAH.

YOU KNOW WHERE EACH ONE GOES.

UH-HUH, AND THE ORIENTATION, ALSO.

NOW SEE THESE ARE BENT OUT A LITTLE BIT TO THE SIDES.

RIGHT.

THEY WERE ALREADY SORT OF BENT, AND I JUST TURNED THEM THAT WAY.

SO YOU CHOOSE THE BENT WOOD THAT-- YEAH, SO YOU DON'T EVEN HAVE TO PUT A BEND IN IT.

ALL RIGHT.

NOW, LET'S SEE.

LET ME SEE IF I CAN SCOOT DOWN A LITTLE BIT AND MAYBE SEE HOW YOU'RE DOING UNDERNEATH HERE.

LET'S PULL THAT OUT.

IT SITS ON THERE.

ALL RIGHT.

LIKE THAT.

AND ALL THIS PRECISE FITTING ADDS IMMENSELY TO THE STRENGTH OF THE PIECE, TOO.

YOU HAVEN'T GOT ANY PLAY...

RIGHT.

IN ANY SPINDLE, IN ANY JOINT.

WE'RE PULLING THESE THINGS AROUND.

THIS IS WHAT DAVE ALWAYS CALLED CHAIR-O-PRACTORY HERE.

CHAIR-O-PRACTORY.

[LAUGHING] I'LL GET THIS LITTLE-- LITTLE THING RIGHT HERE.

THERE YOU GO.

I KNOW YOU'VE BEEN TEACHING THIS ALL OVER THE COUNTRY, TOO, AND I CAN RECOGNIZE THE WORK OF YOUR STUDENTS TURNING OUT THESE FINE CHAIRS, BUT YOU ALSO HAVE SOME AT MONTICELLO?

IS THAT RIGHT?

YEAH.

I'VE MADE CHAIRS FOR THEM A FEW TIMES.

SO THAT'LL BE GOOD ENOUGH FOR--FOR NOW.

ALL RIGHT.

WELL, THAT'S SEATED.

SO NOW WE JUST HAVE THAT ONE LAST PIECE.

THE COMB, I GUESS.

YEAH, WE'VE GOT THE COMB, AND THE COMB HAS TO BE STEAM BENT.

IT SEEMS A LITTLE THINNER THERE, SO THAT'S A LITTLE EASIER TO BEND?

MUCH EASIER TO BEND.

MUCH EASIER.

SO I SHAPE EVERYTHING FIRST.

I EVEN CARVED THESE LOOPS FIRST.

NO KIDDING?

IN THE GREEN WOOD?

RIGHT.

WOW.

SHAPE IT ALL FIRST, AND THEN IT'S JUST BENT AROUND THIS SIMPLE FORM RIGHT HERE, GOT A LITTLE BIT OF A TAPER RIGHT THERE.

SO THAT'S A SECTION OF A COMB, I GUESS.

RIGHT, 'CAUSE THE FRONT IS TAPERED, SO THAT'S WHY.

AND THEN CLAMP IT ON THIS SIDE AND THEN PULL IT AROUND AND CLAMP IT ON THAT SIDE.

AND THAT'S WHAT THAT LITTLE PLACE IS THERE FOR, THAT BLOCK.

THEN YOU SEE IT'S HAD SOME SPRING BACK TO IT, BUT THAT'S CALCULATED.

OH, REALLY?

OK, SO YOU WHAT THAT'S GONNA COME BACK TO.

NOW, YOU SAY GREEN WOOD.

THAT'S GONNA TAKE LONGER TO DRY THEN JUST DRY WOOD THAT YOU STEAM, ISN'T IT?

RIGHT.

YEAH, YEAH.

IT SURE IS.

AND THE SPRING BACK WILL BE MORE.

YEAH.

BUT YOU JUST FIGURE ALL OF THAT?

YEAH.

I COULD LEAVE IT ON THERE FOR A LONGER LENGTH OF TIME, DRY IT IN MORE HEAT, AND IT MIGHT NOT HAVE HARDLY ANY SPRING BACK TO IT.

OK, BUT YOU JUST KNOW THIS-- I LOOK FOR A CERTAIN DIMENSION BETWEEN THERE AND THERE, AND I GO FOR THAT.

AH, OK. ALL RIGHT.

SO WE'RE READY TO FIT THIS ONE IN AGAIN.

LET'S SEE.

IT'S BEEN BORED.

SO YOU BORE THAT AFTER IT'S SHAPED-- I MEAN--YEAH, AFTER IT'S ALL SHAPED.

AFTER IT'S BENT AND SHAPED.

YEAH.

THAT'S THE ONLY THING I DO AFTERWARDS.

SO NOW... FITTING THEM IN.

NOW LET'S GET THIS AND GET IT DOWN JUST A LITTLE BIT.

SEE IF I CAN GET YOU THERE.

THERE YOU GO.

WOW.

YOU KNOW, THE TOP LOOKS MUCH MORE-- LOOKS MORE DAUNTING THEN THE UNDERCARRIAGE ON THESE WINDSOR HIGH CHAIRS, BUT IT ACTUALLY SEEMS A LOT SIMPLER NOW THAT WE DO IT.

IT LOOKS TOUGHER.

YEAH, I THINK THE UNDERCARRIAGE PROBABLY IS-- PROBABLY IS HARDER.

ONE IS IT'S LESS FORGIVING.

SO IF YOU'RE OFF JUST A LITTLE BIT, THEN IT MIGHT BE MORE DIFFICULT TO GET TOGETHER.

YOU MIGHT BREAK SOMETHING.

WHERAS UP HERE, THESE PARTS ARE SO RESILIENT THAT THEY CAN FLEX AND MOVE WITH YOU JUST A LITTLE BIT MORE.

OH, THAT'S HANDY.

THAT'S RIGHT.

YOU'VE GOT HARD MAPLE AND SPRINGY OAK UP HERE.

WELL, NOW WE'VE GOT A LITTLE BIT OF CARVING HERE ON THE EAR.

YOU HAVE A CHANCE-- WE CAN TAKE A LOOK AT DOING THAT CARVING THERE?

RIGHT.

SURE.

THERE'S LIKE A WHOLE LOAD OF CARVING.

I DON'T KNOW IF WE'LL GET TO IT.

THE KNUCKLE, AS WELL.

GOD.

SO YOU TEST ASSEMBLE THIS AND THEN GET THIS APART AGAIN AND START DOING YOUR CARVING ON ARM?

YEAH, I WOULD MAKE SURE THAT I LIKED THE POSITION OF EVERYTHING.

UH-HUH.

AND THEN I WOULD PULL IT ALL OUT AND START FINISHING IT UP.

RIGHT.

AND THEN--THEN I'D PUT GLUE IN IT AND GLUE IT UP.

HOPE--HOPE EVERYTHING'S OK AT THAT POINT.

YEAH.

OK, SO...

BUT THIS IS AGAIN IN GREEN WOOD YOU'RE GONNA DO THIS STAGE.

RIGHT.

THIS--THIS PIECE HAS JUST BEEN SPLIT OUT OF WHITE OAK.

AND...

SO IF YOU'VE ONLY GOT A LITTLE STICK OF WOOD ABOUT THIS BIG, THERE'S NO REASON YOU CAN'T JUST START LEARNING HOW TO MAKE WINDSOR WORK.

YEAH.

EXACTLY.

SO HERE'S MY CARVING TOOLS.

UH-HUH.

RIGHT HERE.

AND ONE THING I'VE ALREADY DONE IS I'VE GONE AROUND THROUGH THERE AND SCORED THAT CARVING THERE.

AND NOW I'M GOING TO CARVE OUT THE EXCESS.

SO WHAT YOU DO IS YOU JUST... JUST START WORKING DOWN IT.

LIKE THAT.

OK, SO STRIKE IN VERTICALLY... MM-HMM.

AND THEN CARVE UP TO THE SIDE.

ALL RIGHT.

I THINK I'VE GOT THE IDEA.

CURTIS, I'LL TELL YOU WHAT.

LET'S TAKE A QUICK LOOK AT THAT FINISH THAT YOU PUT ON THERE.

THIS LOOKS LIKE IT HAS MULTI-TONE.

UH-HUH.

THIS IS MILKPAINT FINISH?

THIS IS MILKPAINT.

IT'S NOT THE TRADITIONAL WAY THAT WINDSOR CHAIRS WERE PAINTED.

THEY WERE PAINTED WITH PAINT WITH LEAD IN IT.

OH, THAT'S NOT GOOD FOR BABY.

ALL RIGHT.

BUT MILKPAINT.

YOU HAVE A WHAT, A RED UNDERCOAT ON IT?

RED UNDERCOAT, AND I HAVE A BLACK WASHCOAT.

AND MILKPAINT DOESN'T SEAL WELL, SO I'VE GOT TO PUT VARNISH OR OIL OR SOMETHING.

I USE A LINSEED OIL AND THEN IT'S WAXED ON TOP OF THAT.

THAT'S WONDERFUL.

WELL, CURTIS BUCHANAN OF JONESBOROUGH, TENNESSEE, YOU MAKE US PROUD-- PROUD TO BE WITH YOU.

AND THANKS SO MUCH FOR SHOWING US HOW TO MAKE THIS WONDERFUL LITTLE WINDSOR HIGH CHAIR.

AND, HEY, THANKS FOR JOINING ME.

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

WE'LL SEE YOU NEXT TIME.

SO LONG.

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Announcer: 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.