The chairs are progressing well and are now mostly assembled. It was slow going as I only have 1 corner clamp so I would glue and clamp 2 pieces, wait an hour, add the screws, then repeat with the next 2 pieces. Despite that, all went very smoothly until I started attaching the arm support on the 2nd chair. I’d run out of my standard type of 2 ½” screws and found a box a friend had left at my house. After pre-drilling the holes, I started inserting the 2 screws. At about 2/3 of the way in both of the heads just snapped clean off. Had there not still been a gap between the 2 pieces of wood, it would have been fine to leave them in place but unfortunately I had to remove them somehow.
I tried hammering the wood together, using an extractor bit to remove them and adding more screws to pull the pieces together but nothing worked. Finally after a few days of contemplation and frustration, I borrowed my dad’s reciprocating saw and just cut right through the screws at the point between the 2 pieces of wood. I re-glued the pieces together, added a couple of screws (NOT from my friend’s box) and it looked good as new.
Also complete are the inner frames for the seat and back of both chairs. Webbing will be attached to these, and then they will be screwed in place from the inside so the frame remains without any visible connectors.
And now we know: there are different quality levels of screws and the cheap ones are really terrible
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