Making a rustic side chair

To make this chair I'll be using mortise and tenon joinery.  Dry wood is essential for tight joints, especially for the tenons. For this project I've selected Saskatoon pieces that are 1.25" to 1.5" in diameter.  The dates marked on the pieces pictured below show that some were harvested over 20 years ago.

Over the years I've collected hundreds of twigs and branches from wooded areas where I live. I normally date them.

My "shaving horse" is used to securely hold the piece while I use a draw knife to remove the bark, shape, trim and reduce the diameter to a required size. You can build your own shaving horse using plans available on line. 

These are the components for the chair. In this photograph all pieces have been cut to proper length and the ends (tenons) have been sized.  Most tenons are 3/4" diameter but a couple are smaller at 5/8" diameter. The holes (mortises) are approximately 3/4" deep.

The tenon cutter, shown at the top of the photograph can be purchased from  Lee Valley Tools in a variety of sizes

This photograph shows the joinery of the legs and rungs.

Here, clamps are being used to hold everything together and to make final adjustments. In the background is a completed chair that was built over 10 years ago.

Once I'm satisfied with the shape and appearance, it's time to disassemble and sand all the pieces, glue it up and re-clamp everything for overnight drying.

Finally, the seat is made to fit the frame. This seat is made from 1" thick birch that was sawn from a neighbors woodlot. A bit of bark was kept for interest.

The finished chair after a couple coats of satin Verathane.