Norm's Plans - Finished!!

[Harbo]

For quite a while now I have been making Norm's Deck Chair.

It's not that easy with virtually every piece curved and lots of joints.
The thing is then fastened together with a pack of brass fittings supplied by Rockler. The plans are in the form of paper templates which I cut out and stuck to ply.
I've shaped all the pieces, cut the joints, cut numerous slots and drilled the holes for the fixings - all to the plans. Today I attempted to attach the brass - shock, horror the holes etc do not match up!!

Anybody else had problems with Norm's plans on other projects?

Rod

 

[wizer]

oh that's annoying. I seriously thought about buying that plan. I'd have got my self in a right little muddle!

Praps Rockler changed the hardware without informing Norm?

 

[Blister]

Or ------

Maybe --------


" God " has made a Bo Bo

but I don't think he would !! :wink:

 

[Harbo]

Here's some WIP photos:

Assorted bits:

Seat section (Dry fit only - edges still to be rounded off:

What it should look like!:

Rod

 

[andycorleone]

147 USD + shipping for the whole thing is quite a lot :shock: and it doesn't fit is a crime :evil:

the other day I was thinking in made the one from David (the Great British Workshop)

http://www.woodworkingchannel.com/dolph ... ibrary.php

 

[Harbo]

I bought the plans in the UK but the Rockler bits in the States about 2 years ago - they were much cheaper then as I would not have bought 2?
How it turns out comfort wise will decide if I make the 2nd one?

After a bit of plugging and re drilling they fit now - I suppose I should have checked earlier instead of marking out just from the templates?

Rod

 

[TheDudester]

I know that there is errata posted relating to this project on the website.

Regards

D

 

[Harbo]

Dudester - thanks for that I was getting concerned about the seat profile and found this:
"The illustration shows the curved seat slats in both the "major anatomy" drawing and "chair assembly" drawing with the curved part forward. They should be reversed so the curved part is to the rear."

Good job I have not glued it yet - lets hope the tenons match up?

The seat photo shows the front at the front - the dip should be at the back! :evil:

Rod

 

[Harbo]

Hit another problem with plans today - the main back supports for the top crest rail did not allow for the rail being curved. The notch joint should be at an angle instead of 90 degrees - will have to now pack it with a wedge!

Perhaps I should have bought the video where some of these items may have been pointed out? - but that takes all the "fun" away :arrow: (hammer)

Rod

 

[wizer]

Doh why didn't I think of that before! I have the video if you would like it Rod?

 

[Harbo]

Thanks WiZeR - I am on the last knockings now - just the final assembling to do - so any more damage has already been done?

But it would be nice to see how I should have done things.

Can I borrow it or do you want to sell it - I will refund any costs involved?

Rod

 

[Harbo]

Thanks to WiZeR I have now seen the video - Norm makes it look so simple.The only hand tool he uses is a corner chisel to clean out some mortices he could not make with his morticer!

He does pick up on a few things not covered by the plans so perhaps I should have bought the video at the start of the project?
He makes a few jigs to cut the tenons square to the curved pieces and makes a lot of use of his hand-held router with template trimmer and his oscillating sander.

Might even be tempted now to make the second one?

Rod

 

[Jake]

If there are errata, why the **** aren't they inserted with the paper plans?

 

[wizer]

No probs Rod. I remember the first time I saw that episode, thinking: "I'd love to make that, but I'd also love to keep some of my sanity!!"

 

[Harbo]

Well here it is assembled after a very troubled day sorting out the correct fixing for the arms - Rockler's very detailed info differs from Norm's small sketch - Norm was correct in this instance. Putting it together with all the brass hollow rods, washers etc. was a real pain!

Holes to be plugged, sanding and final finishing still to be done - but it can be sat on!! I've been working on it, on and off (mainly off) for 18 months.

Will need some easier projects under the belt before I tackle the second one

Rod

 

[gidon]

Excellent - well done - think I remember the episode where Norm built - it started off with Norm relaxing with some sunglasses on and a Martini or something in his hand - classic!
Cheers
Gidon

 

[Harbo]

Well I have just downed a large G&T sitting on it to celebrate \/


Rod :lol: :lol: :lol:

 

[woody67]

Well done that man!! :shock: :shock: What a beauty! Another 5 years and the family might be able to join you! :wink:

Mark