Once the rear seat pieces are attached, we’ll plug all the screw holes. 

Here is one of the seat pieces.  The pilot hole goes all the way through the workpiece, but there is also a larger hole at the top of the pilot hole.  It’s this larger hole we need to plug.  The hole that goes all the way through the workpiece is made with a normal drill bit.

The larger hole at the top is made with a countersink which attaches to the drill bit.

While the drill bit goes all the way through the workpiece, the countersink cuts only the upper portion of the pilot hole which is what we’ll now plug.  Because we need to plug 60 holes, we need a quick (and accurate) way to make a lot of plugs.  This is where a plug cutter comes in handy.

The plug cutter and countersink come as a pair.  The plug cutter cuts plugs the exact size to fill the holes cut by the countersink.  First, we cut the plugs at the drill press.

You can see the plugs are cut, but they are still attached to the piece of wood. 

So, we slice the workpiece at the bandsaw to release the plugs which we can then use to plug the pilot holes.

The chair is almost done.

It just needs is a little clean up and a coat of tung oil.

Here are the two chairs side-by-side.

I could not be happier with how these chairs turned out.  I even made one for myself (and Fred).

This one is made from ash and is the first one of these chairs that I made.  Well, it was the first successful one I made.  As I’ve mentioned several times, there was a lot of trial and error involved in making these chairs and as part of that process, a lot of unsuccessful parts and partial chair frames.  Hopefully, these blog posts (and accompanying YouTube videos) illustrated how unique these chairs are and how many challenges I encountered designing and building them. 

I never intended for these blog posts (or videos) to be this lengthy, but there was just so much ground to cover.  I’m not sure future projects will be quite this detailed or lengthy.  Still, this project was a great learning experience for me which should make future content even better.  As always, thanks for your interest and feedback.  I look forward to sharing future projects.