Many of the chairs I make have shaped parts, and I've learned that they should feel as good as they look. Over the years, I've tried many tools and techniques and the ones I use now are the most efficient way to make shaped chair parts .that are attractive and comfortable. My layout tools are important, because they help me get a symmetrical shape. I use plastic vellum, a flexible ruler, a drafting triangle, a compass, and a pencil. The technique can be broken down into three steps: First, I rough out the shape at the bandsaw. Then I use an angle grinder equipped with a coarse disk called the Holey Galahad (katools.com, No. 47851 RCB) to shape the concave and convex surfaces. I follow that with a power sander and various grits of sandpaper, a coarse file, and sanding blocks to refine and smooth the curves.
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