DIY Network

Explanation of Project and Using the Chop Saw Create your own unique stainless steel chairs From "Freeform Furniture" episode DFFF-107

Host Amy Devers explains the parts of the demo model and gives an overview of the stainless steel chair base, polyethylene seat and bridge and the glue and industrial-grade felt covering the seat. Then she begins the project by cutting the rods using a chop saw.

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	Amy begins work on the dining room chairs by cutting the pieces for the legs.
	The end result will be these bright white, ultra modern, stainless steel based chairs!

Materials:

Industrial felt
Low density polyethylene
1/2" diameter stainless steel rod
Face shield
Work gloves
Tank of argon gas
Welders mask
Welding gloves
Leather welding gloves
Weather welding jacket
Filler rod
Industrial spray adhesive
Blue tape
Utility knife
Large piece of cardboard
Industrial construction glue
Tape measure

Tools:

Metal-cutting chop saw
TIG welder
Welding jig
Water-jet cutter
Clamps
Drill press
Mallet
Cauls

	Figure A
	Figure B

Using the Chop Saw

Safety Tip: Whenever you use power tools or machines, you need safety equipment. Since you will be creating a lot of sparks using the metal chop saw, you need to wear a full face shield, long sleeves and work gloves.

Note: It is always a good idea to know what you are going to cut and to what size. As a guide, you can do a full scale drawing with the exact dimensions and angles for all the parts of the chair frame. That way when you cut and grind them, you can take them and hold them against the drawing to make sure they are right.

1. Set the metal cutting chop saw to a 45-degree angle to cut the pieces for the back legs (figure A).

2. Check the cut piece against the full scale layout making sure it is the right length and has the proper angle (figure B).

3. Repeat this process, checking each piece for the chair frame against the full-scale layout.

4. The long pieces should always be cut first. That way all of the short pieces can be taken from the cut off.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Plastics
Poly Hi Solidur
Website: www.polyhisolidur.com

Welding Tools and Accessories
Steiner Industries
Website: www.steinerindustries.com

Miller Electric Manufacturing Co.
Website: www.millerwelds.com

Smith Equipment
Website: www.smithequipment.com

Waterjet Services
Flow International Corp.
Website: www.flowcorp.com

GUESTS :

Elliot Monson
Senior Applications Technician
Flow International Corporation
23500 64th Ave. S.
Kent, WA 98032
Phone: 253-850-3500, ext. 593
E-mail: jbailey@flowcorp.com
Website: www.flowcorp.com