So it's been a few years but got a call. So here we go. We'll start with lumber sucks: price and quality. But I bought more than needed. Then the slats were cut.
So this afternoon after my real job they were all cut to 56". Their width is 1 5/8. I ran the edges through a jointer just to knock off the rough spots and cut down on sanding. I've already culled three because of twisting. Down to 25 and need 24. Have another 1x6x10 in the wings just in case. I have the full weekend starting tomorrow so the slats will go through the router for the edges, drill press for the predrill and countersink, and then 2x6s through the band saw for the seat and back supports, arm rests and supports. Will post pics manana.
Not as much headway today. Spent half the day building three of these. Forgot how much fun they were, but they are all bolted and glued. I also popped a belt on the sander. I know I have some back up belts, but having moved this shop around for the third time, I can't locate them. Who knows. Made the trip to Lowes and fortunately they had a couple of 4x36 60grit in stock. Went ahead and picked up some stainless eye bolts at Tractor Supply, so I think I'm good with the hardware. Material cost on this is going to run around $145. That's a jump of about $45 over previous years.
So now it's rough sanding and prepping to make everything look pretty. I'm not good enough to make it on the first go. Or second. The hardest part in this build is making the seat and back supports exactly the same. That's a trick. But I tried something new that seemed to work. I also tried something that didn't work. I wanted to make the butt joint using the band saw instead of a dado stack. No go. Too much swim. Went back to the dado. Dang. I really wanted that to work.
Well today was sand, predrill and countersink day. Eight hours of it. Culled 11 slats. Making a glider so might be able to use them there. Tomorrow is assembly day. Then a final sand on Monday evening. Deliver on Tuesday. That's the plan anyway.