Replies

1. 
   RalphBarker | Nov 04, 2010 12:51am | #1

   The precise geometry of the stool isn't clear from the photo, not to mention the dimensions. Do you have a SketchUp drawing, perhaps?

1. 
   FrankDrackman | Nov 04, 2010 01:37pm | #3

   No Digital Drawing

   It is pretty simple.  The legs are at about a ten degree angle from the top.  They are about 8.5 inches where the meet the top and the top is about 10 inches wide.

1. 
   RalphBarker | Nov 04, 2010 02:48pm | #4

   The Leigh MMT would be a good solution, but you may not want to invest close to a $grand to make free stools for the charity. Absent that, my approach would be to rough-cut the components in batches to start. (Batch size being determined by available lumber, divided by component storage space available, further divided by the tedium factor involved.) Then, I'd do the primary shoulder cuts for the leg tenons on the TS with the blade at the appropriate angle, using a stop block to keep the distance from the bottom of the slab-leg consistent. Then, I'd use a TS tenon jig, with a wedge to do the cheek cuts, leaving one long tenon. Then, I'd remove the inter-tenon waste on the bandsaw. A mark-up template could keep things consistent, perhaps combined with a positioning jig with multiple flip-over stop blocks.

   That still leaves hand-trimming the tenons to fit the mortises, however. I don't immediately see a way around the hand work - absent the Leigh MMT or something similar. Even then, a bit of hand-fitting would likely be required.

2. 
   Reg66 | Nov 04, 2010 01:01pm | #2

   Multiple Mortise and Tenon construction

   Frank,

   Have a look at the Leigh Mutiple Mortise and Tenon Jig at http://www.leighjigs.com/home.php  It's a very well made tool and that's reflected in it's cost. Once set up you could knock out those stools by the scores per hour. You will need to make a beveled insert for the clamp to account for the splay in the legs. Not a big deal. If you decide to go with this tool send me a personal note and I'll explain how to make and use the angled clamp insert.

   Regis

3. 
   birchwoodguy | Nov 04, 2010 09:42pm | #5

   I have to agree with the other posters, the Leigh Jig is the best tool for the job, but is expensive (I still have this jig on my wish list) so the option I have adopted in the past for a similar situation - sloped legs end tenons- is to make a dedicated plywood template to support a router to cut the tenons.  The only trick to the template is the need to have a wedge (slope section) to register against your legs, and to precut the leg end angles to match.  other than that, it is just a matter of carefully laying out and cutting the plywood template so the tenons work out to the correct size when the bushing follows the pattern.  I find a plunge router best so I can control the depth of cut and quickly cut the tenons but not bog down my router by trying to cut the whole depth at once.  If you legs are symetrical then the same patter will work for both legs.  One word of advise: you may find it easier to cut the tenons BEFORE you taper the sides of the legs.  Think about this when you build your plywood template.  You already have a solution for the mortises so that is that, your all set.

   Robert.

1. 
   FrankDrackman | Nov 05, 2010 01:45pm | #6

   Thanks for the Great Ideas

   Thanks to all for the great suggestions.  I spent some time in the shop developing on the template ideas and think that it might work.

    I am also discussing the project with the group and it might make sense to switch to something else.