1 Outlining the chair profile on the units
Once all the units are assembled, place one face up on a work surface, position the template on it, and use a pencil to trace its outline on the stock (right). The back edge of the template should be almost flush with the back edge of the rear leg at its top end. Mark the remaining units, then cut them all to rough size on the band saw (page 36), leaving about % inch of waste outside your cutting lines.
2 Shaping the chair units
Finish shaping the units using a router fitted with a top-piloted flush-trimming bit. Set the unit on a work surface and center the template on top, then fasten the pieces together, driving a screw through each threaded rod hole in the template into the unit. Clamp the assembly to the table and adjust the router's depth of cut so the pilot bearing will rub only on the template (inset). Guide the router against the direction of bit rotation along the edges of the unit, keeping the bearing in constant contact with the template (left). Reposition the clamps as needed.
To round over the outside edges of the two units that will be on the outside of the chair, install a bottom-piloted rounding-over bit in the router and set the depth of cut to reach your final depth in two passes. Secure the unit outside-face up to a work surface and make each pass by feeding the router along the edges of the piece, pressing the bit's pilot bearing against the stock throughout (right). Again, reposition the clamps as necessary.
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