I generally try to learn something new or build something that will be around after I'm gone.
In this case it was to see what I like and dislike about "pocket hole" joinery. I've read MANY posts on different woodworking boards by both avid proponents and avid opponents of pocket hole joinery. Both sides seem to have valid points and I'm not here to agree or disagree with either ... personally I like dowel joinery for places where it works using a Dowelmax jig for precision and M/T when it's called for. I've also nailed a few things together in my time!
At Christmas I was given a Kreg K5 jig and up to this project had not opened the box.
We have a couple of outdoor "on the deck" events coming up and I noticed that a couple of the store bought deck chairs were not going to be participating in those events due to neglect and abuse ... sooo I looked for a plan that would give me an opportunity to "hopefully" quickly build a couple of replacement chairs and at the same time give me an opportunity to try out "pocket hole" joinery.
I stumbled upon this plan => Chief's Deck chair and decided it fit the bill.
I had the K5 and in addition the HD jig for the Kreg. Looking at the plan it was clear the heavy duty jig/screws were called for so I ordered 125 2 1/2" HD screws. 125 screws SOUNDS like a lot .... these two chairs took 134 HD screws! ... and additional 1 1/4 Kreg screws AND additional 2 1/2" and 1/1/4" deck screws. I was out about $30 in screws all tolled.
Regardless, learning to use the jig itself was very straight forward. It took only one serious screw-up (pun intended) to understand the plan's indicators for screw direction ... after that it was:
1) Cut a bunch of pieces for the two chairs (the plan's cutlist did a good job of not wasting material)
2) Drilling a whole bunch of holes!
3) Following the plan steps for assembly ... all clearly described and pictured. (I did use PL adhesive in addition to the screws on the 2x4 joints)
4) A little sanding and I sprayed with rattle can Thompson's clear solvent based sealer realizing that it probably won't really protect but the wood was all pressure treated and cedar so it should age well.
As the pics show these are by no means fine furniture ... in fact I don't think I used my table saw at all ... I used my sliding miter saw for the straight and angle cuts and my bandsaw for the very casually cut curves (meaning I know they aren't perfect but I was going for fast and close).
One thing I CAN say ... these puppies won't blow over in a big wind ... they weigh about 60# each (they've got enough screws in them to account for several of those pounds!)
As far as the "pocket hole" joinery experience ... it IS fast ... I can't say it is particularly "cheap" considering the cost of specialized screws. I'm satisfied that for this project the strength of the joinery is adequate, but I think the use of the "HD" jig/screws was called for. I'll use it again when I want fast vs fine I think.
In this case it was to see what I like and dislike about "pocket hole" joinery. I've read MANY posts on different woodworking boards by both avid proponents and avid opponents of pocket hole joinery. Both sides seem to have valid points and I'm not here to agree or disagree with either ... personally I like dowel joinery for places where it works using a Dowelmax jig for precision and M/T when it's called for. I've also nailed a few things together in my time!
At Christmas I was given a Kreg K5 jig and up to this project had not opened the box.
We have a couple of outdoor "on the deck" events coming up and I noticed that a couple of the store bought deck chairs were not going to be participating in those events due to neglect and abuse ... sooo I looked for a plan that would give me an opportunity to "hopefully" quickly build a couple of replacement chairs and at the same time give me an opportunity to try out "pocket hole" joinery.
I stumbled upon this plan => Chief's Deck chair and decided it fit the bill.
I had the K5 and in addition the HD jig for the Kreg. Looking at the plan it was clear the heavy duty jig/screws were called for so I ordered 125 2 1/2" HD screws. 125 screws SOUNDS like a lot .... these two chairs took 134 HD screws! ... and additional 1 1/4 Kreg screws AND additional 2 1/2" and 1/1/4" deck screws. I was out about $30 in screws all tolled.
Regardless, learning to use the jig itself was very straight forward. It took only one serious screw-up (pun intended) to understand the plan's indicators for screw direction ... after that it was:
1) Cut a bunch of pieces for the two chairs (the plan's cutlist did a good job of not wasting material)
2) Drilling a whole bunch of holes!
3) Following the plan steps for assembly ... all clearly described and pictured. (I did use PL adhesive in addition to the screws on the 2x4 joints)
4) A little sanding and I sprayed with rattle can Thompson's clear solvent based sealer realizing that it probably won't really protect but the wood was all pressure treated and cedar so it should age well.
As the pics show these are by no means fine furniture ... in fact I don't think I used my table saw at all ... I used my sliding miter saw for the straight and angle cuts and my bandsaw for the very casually cut curves (meaning I know they aren't perfect but I was going for fast and close).
One thing I CAN say ... these puppies won't blow over in a big wind ... they weigh about 60# each (they've got enough screws in them to account for several of those pounds!)
As far as the "pocket hole" joinery experience ... it IS fast ... I can't say it is particularly "cheap" considering the cost of specialized screws. I'm satisfied that for this project the strength of the joinery is adequate, but I think the use of the "HD" jig/screws was called for. I'll use it again when I want fast vs fine I think.
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