ALLEN

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Posted in WorkshopFurniture

Introduction: ALLEN

About: I am a product design student who is exploring the opensource culture right now . Lets create together and explore !

This instructable is on building a chair which can be converted into a high chair with storage at the bottom

For the build I have used teak wood planks , and made the whole furniture from multiple pieces to reduce wastage of materials.

It is an experimental modular collapsible piece of furniture, for easy assembly and disassembly. Hope you have fun making it

Step 1: MATERIALS REQUIRED

- Teak wood planks (1 inch , 6 inch , 1 metre )

- Metal rod 10 mm - 18 inch

- Metal pipe 18 mm - 80 inch

- Allen screw (1,4 thread ) - 8

- Canvas cloth - 1.5 metre

- Metal rod 18 mm - 18 inch

- Wood Stain - walnut - 250 ml

- Brush - 1 inch

Step 2: TOOLS REQUIRED

-Sander

-Band saw

-Drill

-Lathe

-Allen key

-Mallet

-Clamps

-Sewing machine

-Flat file

-Chisel

-Sand paper

-Tenon Mortise machine

-Router

Step 3: MAKING THE FRAME MEMBERS

Take the cad drawing and print it on 1:1 scale on A1 size plotter print

Paste the pieces on the wooden planks in the most efficient way possible

Using a band saw cut the pieces in the required dimension

Remove any unevenness from cut pieces using a sander

Mock fit it using the cad drawing

Step 4: CALCULATING TENON MORTISE JOINT

I use the 1/3 formula.The thickness of the tenon is 1\3 the thickness of of the board. i.e. 3/4" material would have a tenon 1/4" thick. The length of the tenon is figured at 1/2 (the width of the board) as a minimum length.

But for the convenience its already added in the cad file

In this step i have used a tenon and mortise machine to get the same result .

Similar results can be achieved by using a chisel and mallet

Step 5: MAKING GROVES FOR INSERTS

Using the CAD drawing cut all the 8 mm grove using a band saw

Using a router make an 5 mm grove

File and sand all the parts

Step 6: FRAME ASSEMBLY

Now using Wood glue insert all the parts of the frame and clamp it .

Let it dry.

Step 7: FINISHING THE FRAME

Now using a router give a chamfer of 5mm all through out the frame .

Followed by sanding using fine sand paper to reduce the sharpness of the edges .

Step 8: MAKING THE METAL CROSS MEMBERS

Cut the 18 mm metal pipe of 18 inches , 4 pieces .

Step 9: ASSEMBLY OF CROSS MEMBERS

Cut 18 mm rod on the lathe to cut 8 pieces of 15 mm length

Make a through and through hole of desired diameter in all the 8 pieces to

Thread it according to the allen screw you have .

Make 5 mm hole on the sides of the rod

Now insert the threaded part inside the rod and weld them

Step 10: FASTENING POSITION FOR THE CROSS MEMBERS

Using the CAD drawings make 18 mm flat drill bit drill it till 4 mm depth on the opposite side of the router grooves ( very important to be careful not to drill on the same side as the router groves )

Now make 6 mm hole through and through the 18 mm flat drill holes for the Allen screws

Step 11: MOCK ASSEMBLY

Using the Allen screws assemble the side frames and the cross members to achieve a steady structure

(if everything went well we would reach this state, as shown in the picture )

Step 12: MAKING THE PATTERN SEAT AND BACK REST

Using the given template cut the pattern of the seat and back rest .

(The red lines are the fold lines in the drawing )

Step 13: STITCHING THE SEATS AND BACK REST

Following the stitching lines provided in the pattern , stitch the seat cleanly.

Step 14: MAKING METAL INSERTS TO HOLD THE SEAT AND BACK REST

Cut the metal rods of 10 mm , 2 pieces each of the following dimensions.

10.5 inch - 2 pieces

3 inch - 2 pieces

8 inch - 2 pieces

Sand the ends of the rod for easy insertion and removal .

A nice detail can be added by using metal lathe to make the ends of the rod round .

Step 15: FINAL ASSEMBLY

SEE THE FINAL ASSEMBLY VIDEO AND FOLLOW

HAVE FUN !

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    2 Comments

    Excellent work! I love projects like this that require multiple disciplines and combinations of materials. Great instructable too. That mortising machine looks like a beast! :)

    1 reply

    Thank you so much , the mortising machine is really old .