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I thought I would show a few pics of how a seat is formed....
First I make a template....1/8" melamine. Then draw the seat line and the leg curves on the edge. I mark them all and then go one at a time through this rough stage. Soon I will line them up and fine tune the shape so they are as close as possible to identical.
Using a Grex die grinder I chase the inside of the line to establish a groove. This is like painting the edges with a brush and then using a roller to blend.
The die grinder is more easy to control then the angle grinder with Arbortech. By turning the seat in the vise I can keep in good position and control.
Then the Arbortech bulks out the seat working carefully to the grinder groove.
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