Bees Wax

Wax on, wax off (but mostly wax on)

The final coat of bees wax and the rubber is ready to be put on after it dries.

Sanding Job

After a successful gluing session, it was time to sand the chair.

In total it took me a day of sanding to sand the chair to its best smoothness - however there are still some small pieces not fully sanded. I used 80 paper to start with and worked my way down to 1200.

In hindsight, I should have used an electric sander to start with and then hand sanded the finish to obtain a better smoothness. Next time.....

Gluing the parts together

After a few prototypes, I was ready to commit to gluing the real thing. I wasn't sure if my dowel system would work properly, and I had to drill half way into the end pieces to allow for more support to the end pieces, especially since I was going to be doubling up on the rubber weave on both ends.

DXF cuts

After a successful tip from my colleague at work I found a place that routed my parts in Dandenong

This is a box (one of three) of my cut parts

Final DXF File

I've sourced my plywood and this is the final DXF file I will be sending to the routers.

I need 25 pieces to make up 450mm. There are 2 end pieces 23 cut pieces and 23 non-cut pieces.

Rubber Material

I took photos of the final rubber material contrasted against the 1:1 prototype to see the colour contrast and to imagine how the final product will look.

Final Prototype

The laser cuts proved a success, so i added ribbon between the pieces to simulate where the rubber would go. I worked out I need 15m of rubber and I sourced 18m.