How would you shape this??

[MilDoc]

LOML wants replacement wood arms for a chair thats been in her family too long to remember. I can use an old arm as a template to cut the new arm, but how would you shape the left end in the picture, where your hand would be if sitting in the chair?

[gjbivin]

If it were me, I would glue a small piece underneath the end for the "underhang", then cut the profile on a bandsaw. Rasp and sand to taste.

[woodrowB]

If you're making 2 arms(sounds like you are), use a bandsaw and cut from 1 piece with the 2 arms nested in opposite directions. Does that make sense? Then finish up the shape with rasp and sander. Easy peasy.

p.s. My Grandpappy retired from Ft. Hood and settled in Copperas Cove, so I know it well. Probably not many on this forum that do.

[jziegler]

What about using the original as a real template using a flush cut router bit? I don't know what size any of the curves are, but looks like it may be possible. So, my first thought would be rough cut on the bandsaw and shape with router.

Jim

[LarryG]

I'd do as Jim suggests. If the new arm is too thick for a router bit's cutter length (and it looks like it might be) to cut all the way across, use the old arm as the template for the first pass, then remove it and let the bit's bearing follow that first pass to make the second pass (and a third, if necessary).

IOW, for the first pass the old arm is the template but for subsequent passes the new arm serves as its own template.