This version of the
Zig-Zag chair was made with my student Eduardo Acklas, a printer
by trade. We began making the panels from smaller boards, with
dowel joints and PVA glue.
After prepping the
boards we began to make them into panels, each of which has
three boards joined together. We drilled matching holes in the
edges and reinforced the joints with dowels.
Glued-up panels are
more stable; they prevent warping and cracking.
With the panels
assembled and cut to size, we made the fingers of the joint of
the seat with the back, using a table saw with the slight
inclination of 8 degrees, the angle of the back from vertical.
Next we made the cuts
for the joint where the base pedestal meets the angled support
of the seat, with the table saw set at 22.5 degrees, two of
which yields the desired angle of 45 degrees.
On the rear surface of
the seat back we cut a shallow mortise, which serves as a handle
when moving the chair. We used a router to remove most of the
material, then finished up with a chisel and sandpaper.