Reuse oak with mold cleaned and used to create a Bench + Chair. Using a jig to set angle and height to construct steel frame piece by piece to fit.
Initially designed as a task arm chair which then evolved into a casual dinning chair only to then be influenced by the found oak reuse to become a hybrid in order to take full advantage of all the character of the wood.
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Unlike the few other pieces I initially tried to plan the design of the chair. Starting with sketches and Rhino to rough out proportion, dimensions and formal qualities. Once the basics were established I went through a series of quick ink sketches for the frame until I found something that seemed to work with the lumber I had hand picked.
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First day of fabrication started with taking a seat and decided what I was to actually do, because I was rather partial to the mold rot I decided not to cut that bit off and leave the seat wider than the back. Once that was decided I started to test out detail ideas particularly the embedded steel angle. Post this it was on to assembling a jig to hold the pieces for the future steel leg fabrication.
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Day two of fabrication began with securing the seat back to the embedded steel angles using piano wire which had to be ground down to size for a snug fit. This would ensure the wood from breaking away from the steel angles. next was mocking up the legs and establishing the technique to cut and bend the steel.
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The third day of fabrication all centered around building the actual legs/ support base of the mockup and getting everything plumb, level, aligned, attached and welded. Their were some tricky corners that took some clamps and a whole lot of thinking and mark/measuring to get things to line up and work. All the thinking required a break and snack of red tangos. Once everything was welded I was anticipating the need up additional supports/ struts but to my pleasant surprise after all the welding it was quite solid and stable.
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Day Four was the last day of fabrication and it consisted of finish welding, grinding, sanding and cleaning the steel and wood in preparation of finishing.
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The fifth and final day was more laborious than I initially anticipated. As a result of embedding the steel into the wood and only using a pin and welding connections the wood is un-removable, hence, the finishing has to be done in one piece. This meant that for each material had to be masked and finish separately but together. I also ended up having to touch up the steel since the tape affected the finish upon removing.
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