We will begin taking orders for the “Family Tree of Chairs” letterpress poster at noon Eastern on Wednesday, July 28. The cost is $33 plus domestic shipping. There are only 200 posters.
This 16″ x 20″ letterpress poster is gorgeous. And I do not use that word lightly. The image was drawn by Lee John Phillips based on research (and opinions) from me, George Walker, Peter Follansbee and some other history nerds. It was printed via letterpress in New York on thick cotton stock. The image will be used as the endsheets for my forthcoming “The Stick Chair Book.”
This poster is a (probably insufficient) attempt to recoup some of the expenses in making the image and printing up the book’s endsheets. In other words, we’re not trying to turn a profit with this poster – we’re just trying to make something nice that will help cover some crazy expenses for a book.
Also worth noting: I had to increase the price $3 from our earlier announcement because we are building a custom flat cardboard box for the posters. The paper is too thick (.027”) to ship in a tube.
If, by some miracle, this poster manages to break even in the end, I might consider a new edition in a different ink color. But no promises. I’ve flushed away too much money on posters in my life already.
Not everybody who has to make wedges owns a band saw. In the third instalment we take a look at how to make them without power tools.
See the first and second instalments of the series here and here.
Making wedges without a band saw is not any more difficult than with a band saw. In fact it might even be easier. Especially if you don’t own a band saw.
You will need a chisel and a block of wood that you clamp in your vise.
Making wedges with a chisel
Select a suitable piece of wedge-wood. I usually use oak, as this is abundant where I live, but you can also use hickory or ash if that is available to you. Make sure you use dry wood; you don’t want your wedges to shrink after installing them.
The final size of the wedge is approximately 1-1/2’’long, 5/8’’ wide, and 3/16’’ at the thick end. I start with a board of around 5/8’’ thick, sawed to the length of the wedge (1-1/2’’ to 2’’).
Making 1/4″ billets
Stand the board upright on top of your workbench (use a piece of scrap wood if you are afraid of damaging your workbench) and split the piece into 1/4’’ billets. These are your (slightly oversized) wedge blanks.
For shaping the wedges, you will need to make a simple block with a notch sawn out of it. You rest the wedge against this block when you shape it with a chisel.
It ain’t much, but it’s honest work
Secure your wood block in your vise and lay the wedge blank flat on it.
Use tapering cuts to make the wedge shape. I don’t use a mallet for this step. First, start a cut near the tip of the wedge (closest to the block). Then move slightly away from the tip and make another cut. The third stroke starts around the middle of the wedge and last stroke near the end of the wedge.
Make tapering cuts, starting near the point and work your way backwards to the end.
Turn the wedge over and make the same tapering cuts on the other side. It takes about two times on each side to make a wedge, depending on how much material you take off. Better to take it slowly if you’re a beginner.
I usually make a bunch of wedges rather than making just enough for one project. Even if you don’t make that many pieces of furniture, it is nice to have some extra wedges on hand.
Finished wedge
Re-using old wedges
Don’t throw these away!
After I trim the tenons on my chairs, I don’t throw the excess away. It is very easy to make another wedge out of them, providing they aren’t too short. This is another reason to make your wedges slightly longer to begin with — you might get two or three uses out of it.
Place the amputated-tenon-wedge on your block of wood and use a chisel and mallet to chop away the bits of tenon glued to the sides. They should come off easily. Mind your fingers as you do this step. I find it easiest to rest the back of my chisel against the wedge and tap it from above.
Remove the tenon material with a chisel
Re-shape the wedge as described above, using the wood block in your vise. This only takes a stroke or two, so you have a new set of wedges in no time.
Using scraps as wedge material
I often have pieces of oak leftover from chairmaking or other projects. This is perfect material for making wedges. Part of an old oak leg or stretcher can be an excellent source of wedges. I have also used old oak tool handles and offcuts from levelling chairs. Make sure the wood is in good condition, especially with older tool handles.
Old tool handles, parts of legs or stretchers, offcuts from chair levelling – these can all be turned into wedges.
Saw the wood across the grain into the length of your wedge (1-1/2″ – 2″) and shape it as described above.
Making wedges with an axe
I made my first wedge when I had to handle an axe and needed a wedge. I didn’t have any idea what I was doing at the time so I grabbed an oak stick and shaped it into a point on one end with my single bevel hatchet.
Axing a wedge
Once you glue the wedge in place, you can saw off the excess and make it into a point again. Et voilà: Another wedge.
Finished wedge for axe heads.
This method is very useful if you need to make wedges that are significantly wider than the wedges you normally use for chairmaking. And they can be used for splitting logs if you make them big enough.
Some uses are:
Wedges for axes / adzes
Wedges for thick table legs
Wedges for yo momma’s a$$
Troubleshooting tips
–The wedge tip has become too thin at the tipor the tip is bent over: Place the wedge flat on your block and use your chisel to remove the tip (across the grain). Shave the wedge again if too blunt.
-The wedge has curved grain: Curved grain is not a big problem in riven wedges. I have used wedges that had a crook in them without any issues.
-I am having a hard time shaving the wedges to their desired thickness: They come out too flat. It is a common mistake to take material away evenly over the whole wedge. Use tapered cuts starting from the tip of the wedge and only remove a little material at the butt end.
Have anything to add about making wedges? Let us know in the comments section!
Note: This entry has been updated to fix an embarrassing geometry mistake. The repaired paragraphs are in italics.
Wedges for stick chairs must absorb a lot of shock so they don’t snap when you install them. So I steer clear of weak (sycamore) or brittle (ebony) woods.
Most of my wedges are oak or ash, species that are plentiful and inexpensive. I don’t think I’ve ever snapped an oak or ash wedge, even when I’ve struck them at odd angles. I have used walnut and cherry wedges at the request of customers. They work, but you have to be deliberate when hammering them in because they will snap.
The grain in a wedge should run along its length, from its thin tip to its fat end. For chairs, I use wedges that are 1-1/2″ long. The fat end is between 1/8″ and 1/4″ thick. The tip comes to a sharp point. If I need a blunt tip for some reason (say the tenon is loose and shallow), I’ll snip off the pointiness.
The angle of the wedges I use is usually somewhere between 4° and 10°. The shallower angles are easier to hammer in, but the wedge is more likely to crack. A wedge with a larger included angle can cause the wedge to bounce out of the tenon when you hammer it in. The solution is either to hit the wedge harder until the wedge hopefully grabs, or switch to a wedge with a smaller included angle.
Wedges with included angles smaller than 4° can work, but the wedge is even more likely to snap off when struck.
Wedges With & Without a Sled
You can make wedges without a jig on the band saw by using the saw’s miter gauge. Crosscut a 5/8″ x 1-1/2″-long chYou can make wedges without a jig on the band saw by using the saw’s miter gauge. Crosscut a 5/8″ x 1-1/2″-long chunk off a board that is about 6″ wide. Set the saw’s miter gauge to cut on-half of the angle you desire (i.e. 5° off 90° for a 10° wedge). Put the chunk on the miter gauge and cut off a thin sliver. Flip the chunk over – end grain-for-end grain. Slide the chunk toward the blade and make another cut.
You will quickly figure out where to place the chunk so that you make a perfect wedge. You can make wedges with thin points and blunt points.
Keep flipping the chunk over and over. Make wedges until your chunk is so small that it feels dangerous to make the cut while so close to the saw’s blade.
You can also make a dedicated wedge jig for the band saw’s miter slot that has zero clearance to the blade. This jig is shown above. It is permanently set at 5° off 90° and makes it easy to position the chunk of wood and slice a perfect 10° wedge.
The disadvantage to both of these miter-gauge methods is also its advantage. The technique makes it easy to make different wedges. By moving the chunk of wood left or right on the miter gauge, you can make wedges that are fatter or skinnier.
People need food and stick chairs need wedges. They say that there are as many recipes for Spaghetti alla Carbonara as there are Italian housewives. I say there are at least three good ways to make wedges. None of them unfortunately include either pancetta nor Pecorino Romano, but you can’t really expect that from wood. In a mini series of three blogposts, we (Chris, Rudy and me) will share each our way of making them.
To make wedges with a band saw, you need the following:
A randomly sized scrap block of wood (in this case some 24mm Birch ply). Another scrap block of wood with the grain going more or less perpendicular to the long sides. The latter is important, as a wedge with cross grain will be hammered into mush by the first whack from the lump hammer. You also need a knife. And a pencil. And, of course, a band saw. Duh.
The largest block of wood is for the jig. Start by drilling a hole in it. You’ll use it to push and pull the block when you’re sawing out the wedges. It’s not necessary, but unless you’ve got sticky fingers (I don’t wanna know why!) by default, it makes things both easier and safer.
With the hole drilled, it’s time to mark out the size of a wedge onto the jig. But first, make sure that the scrap wood you’re using for the wedges is the size that you want it to be. Its thickness needs to be slightly more (1/16″ is enough) than the diameter of the mortise. So if your mortise is 5/8″, I’d aim for a wedge that is just a tiny bit wider. That way the wedge won’t leave a gap. Second, the block needs to be as wide as you want the length of your wedges to be. When wedging chair legs, I keep the wedges at around 1-1/4″. When I’m wedging short sticks for the arm, I usually end up at around 1″ length. You’ll figure it out.
Use the wedge block itself to mark out a wedge on the jig, by skewing it a bit in over the edge and drawing along its edges.
I usually make my wedges around 1/4″ thick at the top.
With the wedge shape drawn up, cut the notch out. Be accurate. If you make a wonky notch, you will have wonky wedges.
Use the fence to position the jig block toward the band saw blade. You’ll slide the jig back and forth between the fence and the blade so it needs to runs freely, but as close to the blade as you get it. Set the blade guide as low as possible to ensure precise cutting.
Start the band saw. Push the wedge block into the notch as shown above and push forward toward the blade. Push all the way through and pull back. You’ll soon find out that if you do this carefully, the wedge will be neatly pushed out to the right side of the blade when you pull the jig back – getting you ready for the next cut. Flip the wedge block over and you will square it off when cutting the next wedge. Pull back, flip again and on you go. You are now a Human Wedge Making Factory™. Be sure to make a bunch while you’re at it!
Finally, before using the wedges, I like to sort out the best ones. Which are the ones with the straightest grain and the most consistent shape. This is also where the knife comes in. To make it easier to hammer the wedges in, I taper them a bit with my knife. That way the wedges won’t bruise the edges of the mortise and they’ll enter the kerf easier.
I posted a photo on Instagram of our breakfast nook and got a lot of questions about the table and chairs shown.
The chair on the right is from “The Anarchist’s Design Book,” and the chair on the left is a prototype lowback I built for “The Stick Chair Book” (out in October). The gateleg breakfast table, however, hasn’t been in any book or magazine.
I have uploaded a drawing of it to the SketchUp Warehouse. You can download it for free. The model is accurate, except I didn’t draw in the bevel on the underside of the top. (The bevel is 1” x 1/4”.)
The table is simply made. The legs are joined to the aprons with mortise-and-tenon joinery. The folding top is attached to the stationary top with butt hinges. And the gateleg is attached to the table’s base with butt hinges as well. The table base is attached to the wall with a French cleat. Then I screwed through the cleats to secure the whole thing – it’s more like a built-in than a piece of freestanding furniture.
The whole thing is made from soft maple and finished with the linseed oil and wax finish that my daughter Katherine makes. You can learn to cook it yourself here.
Lucy and I eat breakfast together at this table every morning and watch the sun come up over the buildings in downtown Covington. And when we have a dance party in the kitchen (it has happened) we fold the table against the wall.
— Christopher Schwarz
Another beautiful morning in our neighborhood in Covington.
