Introduction: Folding Chair
In the net I found a picture , which shows a very interesting folding chair. The special feature is that the complete chair is sawn from a plate (about 90x60cm) and when folded only as thick as the original plate.
Step 1: Planing
After the photo I made a drawing with Corel Draw . It took a while to
get it together, but I think I came pretty close to Leo Salom's original (which of course is legally protected, so I can not publish the plan and dimensions here).After I was satisfied with the plan it was exported as a jpg image, this image printed in the poster program in the correct size (image 4) and the nine A4 pages glued together to form the finished template
Step 2: Template Building
In order to be prepared for ev. Demands / structures I decided to do some more work and to build a template. This is made of 8mm beech plywood. Unfortunately,
due to my work obsession, no pictures (which, however, largely correspond to those in the construction of the prototype).
Grind the plate, glue the template on, contour the outside with the band saw, saw out the rest with the scroll saw (picture 1). Difference to the prototype: The contours are sharpened exactly on the lines of the template, all edges are easily broken (picture 2).
Step 3: Saw Chair Parts
I have printed out a second template and stuck together. In retrospect, I would have just hang up the template parts and need to trace - but please.
The plate (15 mm birch plywood) was ground flat (Fig. 1), dedusted and the template glued on (Fig. 2).
The outer contour was sawn with the band saw (Fig. 3). Leave some distance to the line. The further saw cuts were made on the scroll saw. Previously, I put holes for the inner cuts (Figure 4). Then the parts were sawed out (pictures 5-9). After all parts were roughly cut I just sawed along the line along.
Step 4: Milling to Measure
On the template parts I stuck double-sided adhesive tape (picture 1). Then
the respectively fitting two parts were glued together and the contours were aligned with the edge milling cutter (picture 2).
It was done quickly on the milling table. The more accurately you saw, the faster the edge milling (in about 2mm supernatant that goes in a milling pass).
Step 5: Assembling
Since it is a prototype, the fittings do not have tobe especially beautiful. In my fund, I found folding hinges, which were partly too big, but quite suitable for the test.The hinges were placed (picture 1) and the screw holes were pre-drilled (picture 2). Screws of suitable length hold the parts together (Fig. 3). A larger hinge fit for the attachment of the seat (Figure 4). It did not matter to beauty, so I just picked screws from my collection box, even if they did not necessarily match (Figure 5). Main thing, they were the right length.Important note: The hinge for the seat must be screwed on the opposite side to the hinges of the support!Whether my thoughts were correct and everything worked as planned showed a first test, which I recorded by video (see video). You see, everything fits.