To build a Duo of your own, you'll need:
1. My solidworks file (certainly couldn't hurt, anyway)
2. 1 Sheet of 4' x 8' x 3/4" plywood (It'll use less but start there in case you mess something up!)
3. A collection of hand held tools (drill, jigsaw, file, wood rasp, chisel, router, ruler, straightedge, pencil)
4. A table saw is handy for speed and accuracy but it's not absolutely necessary
5. Something to finish it with (paint, lacquer...whatever suits your mood)
6. A good dose of patience and creative appetite!
Follow along as I outline the assembly process!
Step 1: Using the Duo
The Duo pictured is the very first one built and I used it nonstop as my computer chair for over a year. As a design student, I spent a LOT of time in this chair. It's as solid today as it was when I made it.
Step 2: Duo Stool
We'll start with the stool. Gather all of your pieces and your assembly tools (block of wood and rubber mallet)
1. Place both seat pieces back to back
2. Put each leg in. Can't hardly mess this up...they only really work one direction.
3. Splay all three legs out a little and place the small disc into the small slot on the back of each leg.
4. Bring all three legs together to trap the disc. You'll have to work your way around and wiggle stuff to get it all to fit.
5. Once all three legs are upright, place the leg brace in the slots on the bottom of the legs.
6. Tap the brace into place and add the leg locks to each end of the brace.
7. Make sure everything is seated properly and you have a functional stool!
Step 3: Duo Chair
1. Place the two seating surfaces back to back.
2. Fit the four legs into their spots. You want the groove of each leg to face inward. You may need to work a little to get this done.
3. Once all four legs are in place, drop the spreader between each leg.
4. Tap the spreader into its place in the grooves.
5. Make sure everything is lined up properly then tap the leg brace into place as you had done with the stool.
6. Once the leg brace is in place, put the two proper spacers between the legs to keep them parallel.
7. Now place the leg locks to secure the brace to the legs. This will hold the legs vertical.
8. Put the back on the chair by lining up the holes in the back with their corresponding chair part. Tap it into place.
9. Tap the key lock over the lugs sticking out of the back of the chair.
That's it! It's all together.
Remember that you can finish the parts before you put them together but you will mess up the finish putting it together. You can see in some of the photos that I sprayed mine with clear urethane after I assembled it. It works for my purposes. If I was using a clear finish like this again, I would finish each piece, put it together, then go over the entire chair again.