Miter gauge extension
1 Preparing the backrest rails and slats
The backrest slats are joined to the rails with half-laps. Outline the rabbets at the ends of the rails and the dadoes in between, making them as long as the rail width and as deep as one-half the stock thickness; leave % inch of space between the outlines. Install a dado head on your table saw, adjust it to maximum width, and set the cutting height. Attach an extension to your miter gauge. Saw the rabbets first, then work from one end of the board to the other to cut the dadoes (right). For each channel, start by defining one shoulder, then make a series of passes until you reach the other shoulder. Hold the rail flush against the miter gauge extension throughout (Note: Guard removed for clarity.) Follow the same procedure to saw matching rabbets at both ends of the slats.
Drill two clearance holes at each end of every slat, then spread glue in the rabbets and dadoes of the backrest rails. Set the rails face up on a work surface and install the slats with screws (left), making sure their ends are flush with the outside edges of the rails.
Miter gauge extension
3 Attaching the backrest to the main body
Set the backrest on the side rail cleats, leaving a 3/e-inch gap between the backrest and the last slat at the top end of the main body. Then position two butt hinges across the seam—one at each end—centering the hinge pin on the gap between the pieces. Mark the screw holes, drill a pilot hole at each mark, and screw the hinges in place (left).
Make the two racks from lengths of l^-inch-square stock. Starting about 2Vi inches from one end, cut a series of notches along the top edge of each rack on your band saw. The notches should be % inch deep, angled at 45°, and spaced about 2 inches apart. Mount the racks by first fastening spacers the same width and thickness as the cleats to the side rails directly below the cleats (see anatomy, page 44). Then glue and screw the racks to the spacers, aligning the top edge of each strip with the bottom edge of the cleat (right). Finally, attach the backrest support stops to the top edge of the racks, flush with the back ends.
5 Attaching the backrest support
Assemble the backrest support with half-laps (page 49). Fasten the top end of the support to the chair with a piano hinge. Cut the hinge to the length of the support rails and screw it to the inside face of the top rail so the hinge pin extends just off the edge. Next, seat the bottom end of the support in one of the rack notches and tilt up both the support and backrest so the free piano hinge leaf is centered on the fifth slat from the bottom of the backrest (right). Mark the screw holes and drill a pilot hole in the slat at each mark. Turn the chair over and screw the hinge to the slat (inset).
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