Arms for a Stick Chair

The following is excerpted from “The Stick Chair Book,” by Christopher Schwarz.

“The Stick Chair Book” is divided into three sections. The first section, “Thinking About Chairs,” introduces you to the world of common stick chairs, plus the tools and wood to build them.

The second section – “Chairmaking Techniques” – covers every process involved in making a chair, from cutting stout legs, to making curved arms with straight wood, to carving the seat. Plus, you’ll get a taste for the wide variety of shapes you can use. The chapter on seats shows you how to lay out 14 different seat shapes. The chapter on legs has 16 common forms that can be made with only a couple handplanes. Add those to the 11 different arm shapes, six arm-joinery options, 14 shapes for hands, seven stretcher shapes and 11 combs, and you could make stick chairs your entire life without ever making the same one twice.

The final section offers detailed plans for five stick chairs, from a basic Irish armchair to a dramatic Scottish comb-back. These five chair designs are a great jumping-off point for making stick chairs of your own design.

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The arms can be the simplest part of a chair. If you’re lucky, you might find a branch in the woods that grew into the shape of a perfect arm. Or the arms can be as basic as two straight boards: one for the right hand and one for the left.

If you like, you can make a C-shaped arm that wraps around the sitter by gluing three sticks together – one for the sitter’s right hand, one for the spine and one for the left hand.
On the other hand, a chair’s arms can have insanely involved joinery – mitered scarf joints or curved half-laps (for starters).

And if that’s not enough of a challenge, try steambending, where there’s a significant risk of chuck-it-in-the-trash-and-start-day-drinking failures.

With dozens of methods available, deciding how to make the arms of a chair can be daunting. So, let’s begin with some basic principles.

The Goal of the Arm
The mechanical goal of every arm on every good stick chair is simple: Avoid short grain as much as possible. If you plan to build your chair with two separate, disconnected arm pieces, then things are fairly simple. You can easily find two sticks to do the job and avoid weak short grain.
The troubles begin when you want your chair to have what’s called an “armbow” – a curved arm that wraps around the sitter from her right hand to the left. How in heaven’s name do you avoid short grain with a C-shaped arm? There are several strategies:

• Find a curved branch that looks like a 90° bend. Saw it through its thickness (called “resawing”) to make two identical curves. Then join the two 90° curves to make an arm that curves 180°. Or get really lucky and find a curved branch that is perfectly C-shaped.
• Take a straight stick and use steam to bend it over a form to make a 180° curve.
• Saw up a bunch of thin (1/8″-thick) pieces of veneer. Apply glue to their faces like spreading butter on bread. Bend them over a curved “form” that represents the arm’s final shape. Let the glue dry. This is called “bent lamination.”
• Purchase “cold-bend hardwood,” which is flexible when wet. You bend it over a form (similar to steambending but without the steam). When it dries, it keeps its shape.
• Create a “pieced armbow.” This is where you use three or four chunks of wood that are sawn to a curved shape. You glue them up in a way that eliminates short grain, sometimes adding a piece called a “shoe” to the top to shore things up.

Typical Dimensions
Arms can vary quite a bit. A steambent arm might be 1″ thick and 1-1/2″ wide. A pieced armbow might be 1″ thick and 2-1/2″ wide. A curved branch or root can be a whopping 2″ thick and 4″ wide.

The arm has to be strong enough that it won’t crack during assembly or in service. And this challenge is made more difficult by all the holes you drill in the arms for sticks. Make the arm too bulky, however, and it might look ugly. It’s a balancing act.

In the world of stick chairs, a typical arm is about 1″ thick, give or take. In a strong material, such as oak, I’ll accept 7/8″ thick. For width, I like 1-3/8″ wide for arms that I’ve bent. And about 2-1/4″ wide for pieced armbows.

If the arm has a shoe, I usually shoot for 1″ thick for that component, though I have seen much thinner ones on historical chairs.

When assembled, the armbow is typically wider than the seat. If my seat is 20″ wide, then my armbow will be 23″ to 26″ wide overall. The depth of the armbow varies according to the design of the chair. If the back of the chair leans a lot, you might have to make the armbow deeper (or not, depending on where you want the hands to end up). Sometimes the hands hang over the front edge of the seat. Sometimes they are in line with the front edge of the seat. Sometimes they are a few inches back. Here’s a good starting point: My armbows are typically about 16″ deep, and that works for most of my chair designs.

All that said, the arms can vary a lot in a stick chair. Don’t be afraid to stray from these guidelines when copying an old chair.

Arms in the Hedge
Among stick chairs from Wales, it’s fairly common to find a chair where the arm’s shape was determined in part by the tree. A tree branch grew in a graceful curve, and it was harvested by a cunning chairmaker. I first learned about this bit of cleverness from chairmaker Chris Williams and Emyr Davies, a conservator at St Fagans. They planted the following idea into my brain: “Chairmaking begins with a walk in the woods.”

That is, you can find a chair’s arms in the branches, and the chair’s design begins there.

During my visits to the forests in Wales, these simple words became real. I looked up into the branches of these craggy Welsh trees and saw the arms of chairs waving back at me. Curved branches are quite common in trees that are part of the intertwined ecosystem of hedgerows and sunken lanes.

When I returned to the United States, I went to the forest to look for arms, but above me I found only legs, sticks and stretchers – straight stuff. The North American forest tends to produce arrow-straight tree trunks as the leaves stretch upward for sunlight.

Of course, naturally bent wood is out there in American forests and towns, but it’s not nearly as common as it is in Wales, where the landscape nurtures these curves.

If you do find curved material for arms, harvesting it, sawing it, drying it and shaping can be a challenge.

Naturally bent wood can possess significant internal stresses. The reward, however, is an armbow with no short grain.

There are two typical ways to use the curve of a branch in an arm.

• With a branch that possesses a shallow curve, use the curve as-is, like in a root-back Welsh chair. These arms act more like a backrest, really. Sometimes they have a shoe (aka doubler) that is carved from the solid arm. Sometimes a shoe is applied.
• With a branch that bends 90°, saw it through its thickness and join the two pieces into an armbow. The joint can be a scarf or a half-lap.

While I have looked for arms during many walks in the woods, most of my success has come from “walks by the stream.” Trees that grow adjacent to a stream can have roots that bend from the bank then plunge down. Sometimes erosion can expose these bent roots. They are ideal for arms. (Thanks to chairmaker John Porritt for showing this trick to me.)

Steambent Arms
Steambending is challenging, time-consuming and there’s always the risk of failure. Despite this, I have loved it since I bent my first comb in 2003. You need a steambox, a way to make steam (I use a wallpaper steamer), a bending strap and a form. The biggest challenge, however, is getting the right wood. The grain has to be dead-straight along its length, or it is likely to split while being bent. Air-dried or green wood bends the easiest – it still has lots of moisture in it, which helps carry the heat into the stick. If the wood has been kiln-dried, it needs to be rehydrated before bending. Cut the stick to shape then soak it in water for a week or two.

But even when you do everything right, sometimes steambending goes wrong.

After steaming the stick for an hour or so, you bend the stick around the form, secure it with clamps and let the stick dry. You can let it air-dry for a couple weeks, or you can build a primitive kiln using some insulating board, duct tape and a light bulb. You want the bulb to heat the kiln to 115°-125° (F). After a few days in the kiln, the arm will be dry enough to keep its shape.

People have written entire books about steambending. The chapter on the comb-back with a bent arm goes into detail on this technique.

Bent Laminations
I’m not a fan of using bent laminations in stick chairs. Laminations usually look wrong to my eye. Basically, making a bent lamination involves sawing multiple thin strips of wood from a board in sequence. You apply glue to their faces, bend the wet mess over a form and let the glue dry. Then you machine the glue-encrusted part to shape.

I am happy to use bent laminations when making contemporary pieces, but in a vernacular stick chair, I’m going to opt for something else because it can look a bit like fancy plywood.

Cold-bend Hardwood
Surprisingly, the easiest way to bend an armbow or comb is using a high-tech material called “cold-bend hardwood” or “comp wood” (“comp” is short for compression). This material has been heated with steam and compressed along its length. When it arrives in your shop, it is wrapped in plastic and is pretty wet (about 25 percent moisture). It also is flexible. You cut it with a band saw and bend it around a form. It’s like steambending without the steam, strap or failure. I’ve had only one failure in 10 years of working with it.

What’s the downside? It’s expensive. A stick of comp wood that will get me three armbows might cost $150. When I sell a chair for $1,400, a $50 armbow isn’t all that big a deal. If fact, it might be cheaper than steambending because there is almost zero risk of failure when bending an arm. However, if you are a hobbyist, your time is your own and you can make these decisions without worrying about the clock.

After you bend the comp wood, you clamp it to the form. Then you can let it air-dry for a week or put it in the kiln overnight. When its moisture drops below 15 percent or so you can take it out of the form. I have found it quickly acclimates to your shop’s equilibrium moisture content.

The comp wood is indistinguishable from wood that has been steambent, so it looks fine in a stick chair. And I go into detail on using comp wood in the chapter on the comb-back with a bent arm.

Pieced Armbows
My favorite way to make an armbow is the easiest method overall.

A pieced armbow is made from two to four bits of wood that are sawn and glued to avoid short grain. A pieced armbow allows you to use flat boards from the lumberyard (or sticks from your backyard) and, with a bit of cleverness in selecting the grain, create a sturdy armbow.

The joinery can be as simple as butt joints and glue, or as showy as mitered lap joints or long scarf joints.

Making a pieced armbow begins with choosing the shape of the arm, choosing the joinery, then making patterns for the parts.

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