We survived Chair Camp!

Once upon a time there was a little blog keeper that found herself too busy woodworking to keep up her blog about woodworking. Sorry folks for the delay but, I am back in action! To make my comeback as grand as possible, I find myself with no choice but to recap the absolutely stellar week we recently had at the Lenox Workshop's Windsor Chair Camp.

At holidays this year, Jeff was so generous to gift Rob, Eoin, and me a week with Joe Graham (the creator of the most beautiful windsor chairs the world has ever seen) learning how to make his unique and stunning Windsor chairs- a sort of woodworking continued education, if you will. The week fell in the middle of March and I think I am just now getting over the aches and pains my muscles felt from those 6 days. Although it was likely the most physically and mentally exhausting week I have ever experienced, every moment at chair camp was a learning opportunity and time spent with wonderful people - I am beyond thrilled to have had the chance to attend.

It all began with a white oak log. Well, actually for us, it all began with an 8 hour road trip from Schwenksville, PA to Jefferson, OH with a U-Haul trailer in tow that we hoped would be filled with successfully constructed chairs at the end of the week. After that, it all began with a log. Joe taught us how to use the rays in the end of a green log to start splitting it into usable chair parts. With some persuasion from sledge hammers, steel log-splitting wedges, axes, and wooden wedges the sucker split apart into 8 parts. Those 8 parts were then split along the tightest grain lengthwise and halved again to provide us with 8' lengths to start with for the continuous chair arm/back.

After laying out the shape and dimensions of the arm/back from a plywood template onto the lengths from the log, we took to the band saw. At the band saw, we ripped along our layout lines to establish a piece that was at least somewhat the size and shape it would finish at as well as remove the bark and sapwood. The still-rough shapes that came from the band sawing were then hand shaped more accurately (and I use the word "accurately" loosely here) with draw knives, spoke shaves, and hand planes.

A huge part of chair camp for me was setting aside my need to make things smooth and square. As it turns out, green lumber isn't going to be smooth or square; Especially when the end goal of the piece is curved, rounded, and shaped by eye. It was an adjustment and, as I said, every moment was a learning opportunity (and a complete 180º from the realm of woodworking that we practice around here).

[I just want to take a moment to recognize the level of physical exertion we have put forth already. At this point, it's something like 10am on day one. We just split logs, held 8' lengths of wet oak level as we pulled them through saws, and shaped with draw knives. Just sayin'. Chair making is no joke.]

Speaking of physical exertion- steam bending. Yep, that's a job that calls on all of your upper body muscles to be at attention.

We stuck our 8' long arm/back pieces into Joe's homemade steam box to cook for 45-60 minutes before we yanked them out and wrapped them around a shaping jig that Joe has perfected over the past couple of decades, I'm sure. Starting with the center of the top aligned with that of the jig, we pulled on the ends to form the top curve of the chair. When that was locked in, we twisted the arms inward and then curved them down toward the ground at an almost-90º angle. After the entire thing was locked into the jig with wedges, we wiped the sweat from our brow and let the damn things sit for 4 days to retain shape as they dried.

 

While the steam bent arm/backs sat quietly in the background, we tended to other things, like shaping. A lot of shaping. So much shaping. Back splats, spindles for under the arms, stretchers for between the legs, and the legs themselves all needed shaping. The blanks of each respective part were cut on the band saw to be just that, rough blanks. So, we broke out the spoke shaves and card scrapers and went to town for what seemed like weeks.

We were in and out of shaving horses and vices like it was second nature. I will say that this type of hand work is somewhat soothing and allows for a great atmosphere to chat with your fellow chair-makers while burying yourself in some impressive shavings piles. There is just something satisfying about watching your rough, square-ish piece of wood slowly become round and smooth and something you like looking at.

"What about the chair seat," you say? What about the seat, indeed. Have you ever heard of an adze? Because I hadn't. And, I'm still not sure that we're friends (me and the adze, that is). Swinging the scoop-shaped axe at just the right angle to chop into the cherry seat blank was nearly impossible for me to perfect. I understood the idea and the physics behind it as I watched Joe demonstrate the technique with ease, but it was a whole other ballgame when I picked it up myself. I'd take 3 swings and need a 5 minutes break.

One of the unique, and insanely comfortable, elements of Joe's chair designs is the hollowed and shaped seat. So, although grueling for those of us that don't do it every day, it was the fastest way to clear out a lot of material relatively quickly to achieve that awesome seat shape. The good news is that no one slammed their shins with an adze and, better yet, everyone found themselves with a lovely, hollowed seat that we then used angle grinders to more carefully shape. I will mention though that there is reason I have no photographs of any of the Lohr kids chopping seats with adze- we didn't want any documentation of the tears.

But then, things started to come together. Seats were shaped, legs had been shaped and attached, the curved stretchers were attached between the legs, back splats had been tenoned and shaped, and arm spindles had been fit and shaped. The splats and spindles were tenoned using a plug-cutting style drill bit to cut them to the proper size at the ends. I know I skipped a lot of process detail in here but, there is really only so much I can write about shaping by hand before people start closing this browser window. Also, let's be real, I took this class and learned a whole lot but am in no way qualified to teach anyone how to make one of these in grand detail.

With the center back splat in place for a height and alignment guide, the arm/back was put into place and was clamped and banded there while we drilled holes through the arms and down at the appropriate angle into the seat to accept the spindles and remaining back splats. This is the point in the week when the anxiety begins to lift and Joe starts to tell you that you're doing a good job. When it starts to look like a chair, the pride outweighs the sleep deprivation and muscle aches.

 

When all the holes were drilled, final sanding and shaping happened quickly and frantically as the big moment(s) approached. The glue up. The most stressful-yet-rewarding part of any woodworking project. ::deep sigh::

Spindles and splats were glued into the seat first but not long after, the continuous arm was carefully pounded onto the top. We'd step back 7-10 paces to eye up the symmetry of the curve and the height of the arms before we'd run back to the chair to take another wail on the area that needed a slight adjustment.

The last task was to chop a kerf into the top of each round tenon that popped through the top of the continuous arm and hammer some walnut wedges down into them to lock the suckers into place (whilst adding a nice touch of contrast). And eventually, we all had chairs. Real, glued, functioning, beautiful Graham-style Windsor chairs.

Some of us got fancy and decided to add some rockers. And those of us who didn't might now be a little bit jealous that they didn't jump on that opportunity. But the art of testing the placement of the curved rockers with reference to your center of gravity in the chair was a wonder to learn and watch.

And as soon as it started, it was over. I could write a book summarizing my gratitude to Joe and Barbara for everything they did for us while we invaded their lives, meals, and home for a week. Joe for teaching us everything he had spent his adult life perfecting while simultaneously dealing with all of our questions/complaints/pointless banter, Barbara for feeding us some of the most delicious food I have ever had, Jeff for sending us on this learning-and-growing adventure, and Ted for being a perfect fourth member to our 'class'. I guess I am also personally grateful to Rob and Eoin for being sort-of okay co-workers sometimes.

Thanks to everyone who had a hand in making chair camp happen for the Lohr Woodworking Studio fellas and me! We are better chair-makers, woodworkers, teachers, students, and overall people because of it.

My First Trip to Hearne Hardwoods

Since day one of working at the shop, I have heard nothing but praise, excited description, and anecdotes from my fellow Lohr Woodworking staff members about Hearne Hardwoods. After 8 months of building positive, high expectations, I finally got the chance to take my first trip out to Oxford, PA to see it for myself.

Spoiler Alert: I was not disappointed

It all began as a live edge, burl slab shopping mission for a recently commissioned project. Because they are credited as being "one of the largest specialty lumberyards in the world," Hearne Hardwood was the destination for such a purchase. Beyond that, Jeff and Rick Hearne have a friendship dating back to years when I was learning my multiplication tables so, it was just as much a trip to visit an old friend.

The part of the mission to find the perfect material for the project was successfully completed. A selection of incredible slabs that matched the guidelines for our project awaited us in one of the massive hangars that are loaded with collections of stacked and dried material. I can't even begin to tell you how extensive their selection is. The project we were shopping for had specific requirements and, the very patient, Ed let us move all the slabs around, inspect their twists/curves, and photograph every possible book match pair. We settled on the beauties you see pictured. By lunchtime, we loaded up the truck with two beautiful live edge, Big Leaf Maple burl slabs! But, alas, our trip did not end here! The rest of the day was composed of a continuation of the most magical woodworking-related adventures I've had to date.

First, I saw the most massive band saw mill that man has ever created. Although the previous statement may be slightly apprentice-naivety induced exaggeration, it is a 67" vertical band saw mill and, as you can see, it's huge.

The gentleman running the mill sits in a booth and controls the machine as it moves the log around, rolling it this way and that way until it's positioned perfectly. Then, the log is wheeled through the band saw blade like butter through a warm knife. It was incredible.

Next, we were given a tour of the house. Although we were warned of it's status as a "construction zone", it was still more beautiful than I can put into words. So kindly escorted by Brian Hearne and Ric Allison, we were led upstairs to meet this beauty; A Ric Allison sofa nearly complete and as stunning as they come. Behind it, stands a banister with Allison-crafted spindles. I can't even wrap my brain around how objects so breathtaking are made yet but, like Jeff's work, they serve as one hell of an inspiration.

Above the living room hovers a catwalk that sits gracefully atop the ceiling beams. An equally-as-beautiful staircase led the way to the catwalk that curved it's way toward a bedroom. The lighting, the ceilings, the walls, the floors; everything about this house was just astounding.

As I had the chance to sit and chat with the man-in-charge, Rick Hearne, as well as Ric Allison and, of course, Jeff Lohr over lunch, I felt surrounded by sheer woodworking genius. As I ingested my chicken ceasar wrap, I listened to these inspirational men just chat over lunch. What was so humbling though, was that they are so kind, personable, and dare I say 'normal'. The idea that such beautiful art and master knowledge of the craft can come from the hands and minds of these gentlemen makes the intimidating woodworking world in front of me seem so comfortable and accessible. Needless to say, my motivation is on an exponential incline.

Then, it was onto the offices. Naturally, every desk in the place has a gorgeous live edge top and a flawless base to match. Every corner as something wooden to admire. Upstairs, we found a George Nakashima table surrounded by seven matching chairs. I had to be reminded that although this a piece of sought-after art, it is also a piece of furniture and furniture is meant to be sat on, eaten off of, and used in a functional way. Let me tell you, that chair is the most comfortable sitting apparatus I have had the pleasure of sitting in (and I have crashed a few quality beanbag chairs in my day). Full disclosure: Even with my huge stature and whopping 113 lbs, I still sat and stood very slowly and carefully as I was self-convinced I would ruin something.

It seemed as though everything I saw throughout my visit was more incredible than the last. It was truly an honor to meet the Rick, Brian, Ric, and all the Hearne Hardwoods staff. I am happy to have snagged this photo with Rick in the office beneath the head of a deer that his son took down with his bare hands in self defense. That statement alone should be some insight into the level of awesome my day reached on Monday. I had built up some high expectations from the flattering words of my co-workers but, my expectations of Hearne Hardwoods were met and exceeded.

I want to thank everyone that took part in my first trip and was so kind to me. My interest, passion, excitement, and inspiration for woodworking continues to grow daily because of people and places like this. I can only hope that in the near future I will get the chance to take a another trip out to this woodworking paradise tucked into the hills of some Pennsylvania Amish country.