Many people worry that cutting down the small trees will kill them and reduce their numbers. In fact, the types of trees required to build furniture have huge root systems that replace the cut trees faster than you would imagine. Small trees that grow in wet areas reach a relatively small maximum size before they die and return to the earth. It is their job to live, die, and decompose into the earth so more highly evolved trees and grow in their place.
Enjoy pruning the trees and treating the places that you use for gathering as gardens. Clear away the decomposing materials and make little pathways. Spending time pruning will put you in a proper frame of mind to see what you like and find what you need. Try to leave enough time to be able to see the beautiful and unusual treasures that are waiting there. A silent prayer of thanks to the trees may further a good feeling for you in the bush.
To construct that fan-back chair, you will need both framing materials and whips (which are for the seat, arms and back arch of the chair.) Build the chair with fresh, green wood. This means that in the summer you cannot gather more than two or three days before using the materials. In the winter and fall, of course, the cold damp conditions will keep your wood in good shape for a much longer time.
What Trees Should You Use?
For framing, you may choose to use willow, alder, birch, poplar, or cedar. If you have a profusion of some other trees growing locally, try them to see what happens and how long lasting the product will be.
Willow
Willow grows in swampy places edged by cattails. You may also see willow growing along roadsides. It often has a smooth gray bark with little diamond shaped points.
There are many types of willow. Often when it is about 7 or 8 years old the bark becomes rough. Willow leaves are elongated and flash silver in the breeze. Willow grows in clumps. These clumps may contain 50 or 60 shoots if they are well established. Sometimes these clumps cover many acres of wetland. Cast your eyes to the tallest willows and there you will find framing materials because the tall trees are also the thick trees.
You will be looking for trees that are 2 1/2 to 3 1/2 inches at the trunk and you will prefer tall trees with few branches.
Alder
Alder will often grow in the same locations as willow. Sometimes they grow side by side with one predominant. Alder grows in the same sort of place as willow. Wet.
These clumps can grow to great heights of about 10 to 25 feet. The bark is dark brown with white horizontal markings. It resembles cherry, but is not so luminous. Alder leaves are very green and pear-shaped with a serrated edge. There are different types of alder with many local names. You can use any of the types.
Birch
There are two main kinds of birch. Yellow birch has bark that looks like mica. It is iridescent and beautiful. And white birch, also called silver birch or paper birch. These trees grow in many different areas -- wet, dry, on the edge of willows, in the midst of poplars. When they are still quite young -- 3 or 4 years -- their bark is brown with markings similar to alder. The difference between young birch and older alder is that birch grows alone as one tree, not in a family unit, unless one has been cut. In this case many will spring up around the cut one. You will eventually be able to distinguish them from one another.
Poplar
In some areas this tree or its relative is called "Balm of Gilead", or simply "Balma". It usually grows in places that once had willow and alder, and are now drier. Poplar grows to prepare an area for more sophisticated, well loved trees. I The wood is hard. The bark is smooth and soft enough to nail but dries very hard.
Cedar
Cedar has been commonly used for rustic building. It has great endurance to weather. It can be left outside; over the years, the bark will strip off, but it is very tough. It is also sticky to work with. The bark is very rough and in the early summer, it wants to peel off like crazy. Working with cedar has its difficulties, but the results can be great. If cedar grows in your location, get to know it. You don't need to rasp the ends of cedar.
WHIPS & TOOLS
A whip is a young tree that has sprung from the root or base of an older tree. It is virtually branchless and is very flexible.
Whips can be gathered all year round. In the winter, spring and fall the weather is not too hot, the bugs are not bad and the absence of leaves makes it easier to see the shape of the branches. The wood is appropriate to use and to cut all year round.
Trees that produce good whips are willow, alder, birch, dogwood, buckthorn, cedar or hazel. Definitely not poplar: It breaks.
You can find great whips along the roadside or beside train tracks because big bushes are often cut down for visibility. Of course new growth occurs and the more they are cut, the better the whips. For your chair, whips about 3 or 4 years old are usually best. From about 1/2" in diameter to 1 1/2 inches is useful. The back, arms and seat require different length and dimensions but if you gather 35 whips of the above dimensions, you will probably find you have what you need.
TOOLS and Other Gear
For gathering materials in swampy areas you definitely need a pair of rubber boots, big enough for felt insoles. Wear good wool socks, tight enough not to slide down your foot and you will be comfortable and safe even on quite snowy days. Of course, at any time of the year, dress for the weather. Always have your arms and legs covered to prevent scratches, bites and sunburn.
Tools
Pruning Shears - With the recent popular interest in gaardening comes the availabilty of wonderful pruning tools. You can purchase nice little folding saws with very sharp blades to cut green wood. Some have replaceable blades; some do not. One advantage of these small sharp saws is that the little blades can fit into some very tight spaces.
Saws - On the other hand, there are bow saws with replaceable blades available for low prices, also designed to cut green woods. The advantage of this saw is its long blade. Fewer passes of the saw make the cut.
Long Handled Pruning Shears - For gathering whips, long handled pruning shears are good. There are many variations. Some have telescopic handles which are good because the longer handles give more leverage and make cutting easier, but you must keep them dry and well oiled or they will get stuck either in the long or short position or one in each.
Anvil Cutters and Side Cutters - The anvil cutter is designed to cut at right angles to the branch. Other uses will put this cutting tool askew. Its drawback is that after a few sharpenings, the blade will no longer meet the cutting bed, although some anvil pruners have adjustable cutting beds that may be raised. Some anvil pruners have ratchet action. No matter the quality or the price you pay, this is a disposable tool. It cannot be sharpened often and will need to be replaced.
Curved Side Cutter (or bypass pruner) can be sharpened more often. There is a huge variety in the quality and price to choose from. These pruners allow more accurate cuts. Both anvil and side cutters are availabe for hand use also.
Rasps - Quality is very important in rasps. Make sure the blade has bite. Blades on rasps can be replaced when they become dull.
A Sharp Knife is sometimes handy.
Hammers - There are many hammers in the world. Get one that feels comfortable in your hand and has a nice flat hitting end, not one that is rounded.
Nail Pull - You'll need a tool to remove misplacedd nailed.
Always wear safety glasses.
Nailpush - It is a magnetic sleeve that can push a nail into a tight spot. The nail punch sets nails into the wood and when the wood dries and shrinks the head of the nail won't emerge above the surface.
Work Table - Make sure you have a sturdy worktable that is well supported. If your table bounces up and down when you hammer, it can absorb the impact from your hammer and cost you time and energy.
Screws and Nails - There are many types of fasteners.&nbssp; Some people choose to use screws. If you use screws, you should first drill the hole and it should be somewhat longer than necessary because, when the chair dries and the wood shrinks, the screws will have to be tightened down. If there is no pre-drilled hole to tighten into, the wood will split.
Nails - are a very fast method. If you hit the nails on the pointed end before using them they become blunt. When a blunted nail is hammered in, it breaks the fibers on the way through the wood. This considerably reduces the possibility of splitting. Spiral nails hold better than smooth nails.A famous rustic builder in the U.S. uses copper nails with big heads. The big copper heads create a surface decoration on the furniture. Galvanized nails are treated in a way that prevents rusting. Rust is bad because it makes the nail increase in size which enlarges the nail hole. When the rust powders off, the nail is weak, the hole is too big, the joint is loose and the chair wobbles and breaks. Buy galvanized spiral nails in the following sizes: 3 1/2", 2 1/2", 1 1/2", 1 1/4". Also buy small finishing nails of 1", and 1/2" or less. It is hard to find all these sizes in any one store. Try to buy in bulk for convenience and economy.
Wire - good to hold small, skinny branches together where no nail is small enough. any wire joint is temporary until the wood shrinks. When the wood dries, it should them be rewrapped with wire, bark, rawhide or ribbon.
ASSEMBLING
You will need approximately six small trees. This number will depend upon the type and height and degree of straightness of trees that you decide to use.
Description of Frame Pieces
You will need 12 pieces that are 25 inches long of various dimensions and shapes, including pieces with forks that are no wider than six inches. These will be labeled from A to L. They will be called stretches.
You Will Need:
- 2 Back Legs (labeled W1 and W2): these will be 32" long, 2-3" in diameter
- 2 Front Legs (labeled X1 and X2): depending on the knee height of the person, these will be 15 to 17 inches long and 2-3 inches in diameter.
- S = a piece for the fan to rest on (approximately 35 inches long): it should be straight and approximately 1 1/2 to 2 inches in diameter.
- Z = a piece to support the small of the back (approximately 20 inches long): it is straight and 1 1/2 inches in diameter.
When you make chairs in the future, use these measurements to determine ones that will be ideal for you. Ask yourself questions:
- Will you use cushions?
- Is the chair the right height, depth, and width?
- What adjustments would you like?
Cutting the Pieces
Cut the back legs and front legs from the root end of the tree because it is the thickest. Your job will be easier with very straight pieces Once you have cut both the front and the back legs (2 of each) find piece X. Because it is long and straight you should choose it before cutting the other pieces. At the other extreme, piece Z usually shows up during the cutting of all the other pieces. Cut everything else 25 inches.
Rasping and Clipping
After the pieces have been cut, you may want to rasp the edges. The exposed wood at the ends of each piece dry faster than the protected wood inside the bark. This tends to cause the bark to split. Rasping helps to prevent splitting.
The rasp is a tool that works like a cheese grater. The many little blades shave the edges from the cut sticks. Grasp the end that is a bump in the palm of your hand. Support the stick and remove the bark and a little of the wood to give the end a gently rounded shape.
Use the bypass clippers to remove little branches that are in the way. If the cut is not clean, you may rasp it too, or you might want to use the sharp knife to clean away any mark that is already starting to peel.
Organizing the Sticks
Organize the 25 sticks. Putting actual letters on each stick with masking tape could save you time and confusion for your first chair.
Choose:
From all the 25" pieces, the 3 straightest and most similar in size (about 2" in diameter) to be the seat and front knee bar. The thickets is A, then B, and the thinnest C.
The next 2 straightest for the top of each side D and E.
The two most similarly forked or wavy sticks for the bottom rung of each side F and G.
One stick with or without a fork. It must be able to lie flat. This is is for the lower rung and the front H. The fork must not be wide than 6 inches.
Two sticks will be the back rungs. The top one, I, should be moderately straight and the lower one J, doesn't really matter.
Last the two thinnest sticks, K and L are diagonal braces.
Hammering
This frame will be fastened together using hammer and nails. Hammering looks easy when done by an experienced person. In fact, it is a learned skill that does need practice and experience.
Finding the Flat Side of the Stick
Begin by laying the stick on a flat surface. You will notice that each stick generally has a flat plane. Even though a stick may look like a corkscrew, on one side it may still have a flat side.
The Frame
Place one back leg W1 and one front leg X1 on the table with their thickest diameter (usually the end nearest the root)flush with the tables edge. Place D horizontally across the two legs about 1 1/2 inches down from the top of the front leg with piece D overhanging the front leg X1 about 1 1/2 inches.
Use a nail that is not so long as to go through the two pieces and out the other side, but that is long enough to firmly join the two pieces together at their thickest points.
Remember: To avoid splitting, bang the nails on their points with the hammer to make them dull. One bang will do.
You may want to use a nail punch to set each nail as you put it in. Or you may want to wait and set them all when you are double nailing. (Double nailing is explained later.)
Remember that the edge of the table represents the floor and that the bottom of each leg must be flush with the table edge in order to ensure a chair with legs that all touch the floor.
With piece D overhanging back leg W1 by about 1 1/2 inches, make sure that X remains perpendicular to the table. Use the nail that joins X to D at the front leg as a hinge. Tilt stick D so that it touches back leg W1 about 2 inches lower than it is attached to front leg X1. Nail it together.
Find one lower side bar E which may be straight or forked and place it across the front and back leg about 3 inches from the floor or table edge. E should extend about 1 1/2 inches in front of the front leg; nail it in place. Then using the nail that joins to top bar D to the back leg W1 as a hinge, tilt the back leg about 2 inches. Nail it. If this is a forked stick, nail only one part of the stick.
We're starting to build now. Follow along and do each step one at a time.
Follow these directions for the other side of the chair, making certain to reverse the placement of the back and front legs, making sure that each side is more or less a mirror image of the other.
When you pick the chair up, the two sides should move as though hinged. This is as it should be. They should not fall apart when picked up. If they do, remove the small nails and start over with larger nails.
Lay the two sides on the backs of the floor with the back of the chair under the worktable and the pieces (D and E) and (F and G) on the outside.
Hang the two sides with the nailed-on pieces facing out from the front legs X1 and X2 from the table's edge.
You should be able to support this structure with your hips, but if you can't, ask for help.
Lay stick A across the two front legs above the protrusions of the top side stretches, F and D. The top of A should be flush with the sides of the sticks F and D. Nail stick A to stick X1 and then to stick X2.
You may remove the table from hanging on the table's edge and stand it on its four legs on the table. It will be very wobbly. It has no braces and only 10 nails. Hopefully, it will be able to stand up by itself. If, not you may need help again.
Ensure that the front legs are perpendicular to the table and parallel to each other.
Place stick G on top of the protrusions of G and E. Its ends should be flush with the sides of G and E. Nail one side to X1 and, making sure that the space surrounding F, G, D, and E is a rectangle, nail F to X2.
From now on, always work with the chair standing on its four legs. This will ensure that all legs will touch the ground. There are a few exceptions to this rule which will be discussed later.
Once you have accomplished this task, turn the chair so that the back is facing you or go to the other side of the table. Add stick H to back leg W1 and W2 above the back protrusions of D and E in the same way that you did at the front. You may pull the back legs together at this point. Extend the stick edge a finger width beyond the the side bars before nailing.
Place stick I on the top of the protrusions of G and E. Its ends should be flush with the sides of G and E. Nail one side to W1 and making sure that the space surrounded by F, G, D and E is a rectangle nail G to W2. The addition of stick I will greatly enhance the stability of the chair.
The chair now has four legs and all of the stretchers. It needs bracing with the diagonal brace pieces. Before you do this, the chair needs to be the correct shape. Look at the chair from all sides. Ask yourself the following questions:
- Does it have right angles?
- Does it look comfortable?
- Is the line between the back legs parallel to the front knee bar?
- Is the back tilted back comfortably?
Manipulate the chair quite firmly until the answer to all the above questions is yes. This is called "racking the chair" and is similar to a chiropractic treatment.
Add the diagonal braces. This will set the shape of your chair. Do not double nail.
These braces go on the inside of the legs on either side of the frame. Use only one nail (as long as possible) at each end.
Double Nailing
Place the chair back on the table. You are about to double nail each of the nails on the four sides of the chair. The addition of these nails will considerably strengthen the structure.
In order to avoid cracks, make sure not to nail on the same grain line as the previous nail. This is the time to set your nails with a nail punch.
Adding the Mystery Pieces
Put the chair on the floor. Piece S goes across the tops of the back legs. You will have to stand behind the chair, looking down at the shape of the back. Imagine yourself sitting in the chair. Slowly turn piece S until where you back will be is either flat or concave. It should definitely not be bumpy.
The back legs should make sharp contact with horizontal piece S. Fasten it to the top of the legs with quite a long nail going straight down through the piece S into the center of the top of the leg.
Piece Z fits in between the two back legs in a position approximately at the small of the back about 2/3 of the way below the fan support S.
Follow the same procedure as with the fan support to determine comfort and you will have to cut the ends; rasp them and fit them in between the two legs; nail through the sides of the legs into the middle of the back support bar, Z. It gives stability to the chair. You can nudge it into place with a hammer.
Congratulations!
Your chair frame is finished! You should have two pieces left over. They are for the seat and won't be nailed on until the arms and back are in place. At this point though, you can put them across the side stretchers and try your chair for the first time. If you notice any serious comfort problems at this point, you can still make adjustments. To tilt the back more, you can undo the diagonal braces at one end, make your adjustments and re-nail.
The Arms
To finish the chair you will need to have about 35 good whips with most of their branches removed.
After they are trimmed lay the whips on the ground side by side about six inches of space between them so that you can see what you have to work with. Choose the six longest and straightest whips (about 7 feet long) for the arch at the back. You'll need five but the sixth is just in case one breaks or ends up not being good enough. Set these aside and don't use them for anything but the back. Then choose the ten sticks that you will use for the arms. These sticks will be very straight for about four feet and of equal (more or less) thickness.
Arrange these ten sticks on the floor in two groups of 5. Then re-arrange these sticks to be in the same order that they will be on your chair. The thickest straightest stick will be first and then thinner and thinner because you should never try to attach a thick stick to a thin one. The thin stick cannot support the strength of the thicker one.
Bend each stick gently before applying to the chair.
Place the largest arm whip behind the lower front bar and in front of the knee bar. Using a small spiral finishing nail, attach the whip to the knee bar in front of the front leg, leaving enough room for four more whips beside it.
Attach the whip to the side of the back leg about three inches above the side stretcher. Use the seat stick as a measuring tool. The arms should be about 23 or 25 inches from the ground.
Until the first arms are nailed to the inside of the lower foot bar they can move, thus changing their position and symmetry. Once the two first arms match, lift the chair onto a table and lay it on its front.
Nail the two arm pieces to the bottom front bar. This is to prevent them and the next eight pieces from popping out.
The challenge is to make the other side match. Use your eyes. When both sides look pretty much the same, you are ready to try whip number two. Work from alternating sides so that you always have an equal number of sticks on each side. These bent sticks exert a great deal of force on the frame of the chair and if the pressure is not kept equal the chair frame could be forced apart.
Applying whips upon bent whips is a trick! The second stick follows the path of the first. Do not nail the second stick to the inside of the lower front bar. It won't move because its neighbor is secure. Nail it to the knee bar as tightly beside the first whip as it will fit.
The arms are shaped like the wings of a butterfly. They slope upwards. Using 1 inch nails (mostly), nail the second stick to the first stick at intervals of about 2 - 4 inches but only where the sticks touch one another. Sometimes there might be a space of about 4 or 5 inches between the nails because of a curve in the stick. Never let go of a stick that you are placing as you nail because it won't be secure until it is attached to the back leg with a small spiral nail.
Continue to add arm whips until there are five on each arm. It becomes easier with each stick. Don't give up!
Tip the chair forward onto its arms, stand behind it and nail the ends of the arm whips to the lower front bar. Arrange them attractively to fill the space.
Clip the ends about 1 1/2 inches from the nail position.
The Back and Seat
The Back
Arrange the long pieces for the back arch in the same order that you arrange the arms, the thickest and the straightest first, down to the thinnest. Beginning with the thickest, fasten it to the inside of the side bar. It will wrap around the outside of the arms. Hopefully this back whip will also support the arms.
Nail it to the long arch support bar about 2 or 3 inches from the back leg. Making a nice curve, nail it in the same position on the other side of the other back leg. Continue down, outside the arms to the inside of the side bar. Nail.
Repeat this process four more times, nailing only to the frame at the side bar and arch support bar. However, on the arch the whips will be attached to each other as they were on the arms. This time there will be no angle as the whips are piled straight up.
At this point you can saw off the extra length at either end of the arch support bar. Rasp. Remember where you put the last nails on the arch support bar -- you don't want to nail through them.
The Seat
You have two 25 inch pieces left over from the frame of the chair. These are the supports for your seat.
Attach the largest right behind the front legs making sure that it it is flat. Attach the second seat bar about 6 inches behind it. It should support the weight of your body.
Cut a piece of whip a little thicker than the seat sticks, 25 inches long and place it on top of the knee bar. Nail every 4 or 5 inches. It should be flexible enough to be molded to the knee bar.
Cut four more whips 25 inches long and place them one on each side of the seat outside of the front leg butting up against the knee bar addition and curving inside of the back leg. Nail in place.
Using 10 to 15 straight, flexible whips, you will make both the seat and the back.
Insert the stick through the back of the arch and bend it across the seat supports butting up tight against the knee bar addition. Nail it first to the seat support that is closest to the front, then put the second nail in the front knee bar. Be sure to dull this nail.
Hold this piece tightly in place and press the whip flat to make it touch the second seat bar. If it pops up, try again. Sometimes it helps to trim the crooked end that is causing the problem.
Continue until the seat is filled in.
Sitting behind the chair you will be able to see clearly the curve of the whips. Pull the curve back and then nail the whip to the back support. It's handy to have two people for this job, but it is still possible with only one.
Continue to do this until all the seat whips are attached. Make sure that each curve is the same. This is essential for comfort.
Lean the chair forward so that the top of the arch rests on a table surface. Now is the time to decide on any design you'd like the back whips to have. Using the appropriate nails, attach the whips to the back of the arch where they touch. Trip the whips diagonally.
Don't forget to set the nails on the seat and the back, the last air of arm pieces, the top arch piece and the frame.
Congratulations!
You're Chair is Done!
Now that the chair is finished, there are a number of suitable oils that maybe used to improve the appearance of the chair, keep it clean and prevent splitting: Tung Oil, Danish Oil, and Min Wax Oil Stain (which is available in natural or several different stains). There is also a product called Wood End Dressing. All these products may be applied directly to the chair with a brush. Pay particular attention to the exposed cut ends which require several soakings.




































