by VijayGupta » Thu Apr 03, 2014 9:45 pm
Tips:
1. I dislike doing the 1" block things. I used a bit of algebra and computed the radius of the curve and used a trammel to mark them out.
2. Used a stop on the drill press to precisely set the screw holes uniformly. Pilot hole and countersink for #8 1 1/4" exterior screws.
3. Use 1/2" plywood scrap top set the gaps between the slats.
4. Round over all edges with 1/8" router bit.
5. Use Titebond III to glue the two slats that hold the seat in place, for extra strength in addition to the screws.
6. Keep the grain as straight as possible, especially on the legs. Grain run-out will significantly reduce the strength of these pieces.
7. Put one screw in each end of all the slats. Then ensure everything's square and go back and add the second screw to each end.