Lumberjack DINING CHAIR User manual

DINING CHAIR
www.lumberjacktools.com
1. DRILL 2. CUT 3. ASSEMBLE

WARNINGS AND SAFETY
Before beginning any project, carefully read and follow ALL safety and opera-
tional instructions for all tools or devices you will be using. Failure to do so may
cause serious injury to yourself or those around you. If you feel uncomfortable
using our tenon cutters or any other tool, STOP immediately. Lumberjack Tools
assumes no responsibility for injury caused to the operator, bystander, or equip-
ment caused by the use or misuse of our tools.
NEVER OPERATE POWER TOOLS UNDER THE INFLUENCE
OF DRUGS, ALCOHOL, OR ANY MEDICATIONS. FAILURE TO
AVOID THESE RISKS CAN CAUSE SERIOUS INJURY OR
DEATH.
ALWAYS WEAR APPROPRIATE PERSONAL PROTECTIVE
EQUIPMENT INCLUDING, BUT NOT LIMITED TO: SAFETY
GLASSES, DUST MASK, AND HEARING PROTECTION.
FAILURE TO DO SO CAN CAUSE SERIOUS INJURY.
DO NOT WEAR JEWELRY OR LOOSE CLOTHING WHILE
WORKING. SECURE LONG HAIR AWAY FROM WORK AREA.
LOOSE CLOTHING AND HAIR CAN BE CAUGHT IN MOVING
PARTS AND CAN CAUSE SERIOUS INJURY.
DISCONNECT POWER FROM THE DRILL AND ALLOW DRILL
TO COMPLETELY STOP BEFORE INSTALLING/REMOVING
TOOLS. FAILURE TO DO SO CAN CAUSE SERIOUS INJURY.
ALWAYS SECURE WORK-PIECE (LOG OR BOARD) IN A VISE
OR CLAMP BEFORE DRILLING/CUTTING. FAILURE TO DO
SO CAN CAUSE SERIOUS INJURY.
BLADES ARE VERY SHARP! USE EXTREME CAUTION WHEN
HANDLING THE BLADES. FAILURE TO DO SO CAN CAUSE
SERIOUS INJURY.
DO NOT USE DULL TOOLS/BLADES. REPLACE OR
SHARPEN THE TOOLS/BLADES IF THEY BECOME DULL.
FAILURE TO DO SO CAN CAUSE SERIOUS INJURY.
TENON CUTTER MUST BE DRIVEN BY A 1/2” HAND DRILL.
NEVER USE TENON CUTTER IN A DRILL PRESS, LATHE,
MILL, OR ANY OTHER DEVICE AS THIS CAN CAUSE
SERIOUS INJURY OR DAMAGE.
PARTS, ASSEMBLIES, AND TOOLS/EQUIPMENT MAY BE
VERY HEAVY. USE APPROPRIATE EQUIPMENT TO LIFT AND
MOVE HEAVY COMPONENTS. FAILURE TO DO SO CAN
CAUSE SERIOUS INJURY.
NEVER ALLOW PERSONS UNDER ANY PART OF THE
DESIGNS. DESIGN MAY COLLAPSE, CAUSING SERIOUS
INJURY OR DEATH.

Getting Started
The plans included in this guide are a simple way to get started making rustic
furniture. These plans assume you have some previous woodworking experience
along with the basic shop tools. The unique thing about making your own rustic
furniture, is that you can add your own touch of character and customize it to any
size or shape you like. Keep in mind that rustic furniture is not meant to be
perfect in shape and form. This unique variation gives each project a feel and
character of its own.
GETTING STARTED - SUPPLIES/SYMBOLS
Tools
●ؽ”, Single-Speed Drill
●Cordless Drill
●Tenon Cutter(s)
●Forstner Bit(s) or Spade Bit
●Chop Saw or Hand Saw
●Vise or other clamp
●Tape Measure
●Pencil
●Sand Paper
●Shop Towels
●Orbital Sander*
●Draw Knife*
Building Materials
●Peeled Logs
●Flat Boards*
●Wood Glue
●Finish of choice* (oil,
varnish, or lacquer)
Protective Equipment
●Safety Glasses
●Gloves
●Dust Mask
●Hearing Protection
●Closed-toed Shoes
Required Supplies
*These items are optional
Drawing Symbols
Note: All dimensions in this booklet are in inches
n21
2in
A
6 in
1 in 2 in
11
4in
1 in 2 in
11
4in
n11
2in
A
n1 in(2x)
11
4in deep
B
C
E
F
D
Front View
Top View
Side View
GH
F
A. Diameter Symbol
B. Hidden Line (shows features
hidden behind solid material)
C. Center Line (center of feature)
D. Center Mark (center of hole)
E. Quantity Note (how many of
feature)
F. Depth (of hole)
G. Dimension (in inches)
H. Tenon Length
Tip
DO NOT use:
variable speed,
cordless, or
hammer drills
to drive the
tenon cutters or
forstner bits.

GETTING STARTED - TENON CUTTING
Log Prep
1. Acquire Logs
Logs can be acquired from a variety of sources,
including: local land owners, tree service
companies, home improvement/hardware
stores, DNR or Forestry Department, and K&A
Log Furniture.
Note: Some designs call for a landscape timber.
The correct size is shown to the right.
2. Cut Logs/Wood to Length
Use a saw to cut the logs to the lengths shown in the desired design. Take
care to cut the end of the logs square/perpendicular to the log body.
Note: The log lengths in this manual are sized for one diameter of log. If you
choose a different diameter log than the one listed in the Parts List, you must
account for the change by: cutting cross-member logs (logs with tenons on
both ends) shorter, or longer (see three examples below).
CORRECT
Ends of log square
WRONG
Ends of log not square
Tip
While no logs are perfectly straight,
we recommend finding logs that are
as straight-as-possible to make
fit-up and assembly easier.
Parts List
Item Qty
Part Name
Size
A 1 Log-A Ø2-½” X 10” Long
B 2 Log-B Ø3” X 10” Long
Tip
It is easier to trim a log shorter than to add
to a log. When in doubt, cut cross-member
logs (logs with tenons on both ends) a little
longer than the plan calls for (+1 inch). You
can trim the excess off later after dry fit-up.
B B B B
B B
3 3
101
2in
2 2 4 4
91
2in 111
2in
10 in 10 in 10 in
A A A
Ø3” Log-B
Spacing is correct at 10-½”
Ø2” Log-B
Spacing is incorrect at 9-½”
Remedy: Log-A must be
re-cut at 11” long
Ø4” Log-B
Spacing is incorrect at 11-½”
Remedy: Log-A must be
shortened to 9” long
31
4in
21
2in

3. Drill Holes (mortise)
Drill holes in the locations shown for the desired design. Always drill the holes
in the center of log unless otherwise stated.
Note: Hole depth should be about ½ x Log Diameter.
e.g. Hole depth for a Ø3” diameter log should be ½ x Ø3” = 1-½” hole depth
4. Cut Tenons
Use a ½”, Single-speed Drill and a Tenon Cutter to cut tenons in the locations
shown for the desired design.
Note: Tenon length should be
(Hole Depth) - ¼”.
e.g. Tenon length for a 1-½” deep hole should be
(1-½”) - ¼” = 1-¼” tenon length
IMPORTANT: Cutting a straight tenon is critical to reduce assembly problems.
GETTING STARTED - TENON CUTTING
Tip
If the log is larger than the Tenon
Cutter will accept, taper down the
end of the log with a Draw Knife.
Log Prep (cont.)
CORRECT
Hole in center of log
WRONG
Hole not in center of log
1/2 x Log Dia
Hole Depth
½ x Log Diameter
Hole Depth
1/4" Gap
Tenon Length
CORRECT
Drill in-line with log
WRONG
Drill not in-line with log (crooked)

After all the individual pieces are completed (cut, drilled, created tenons), the
next step is assembly of the design. Please follow the steps below to minimize
problems during assembly.
1. Sand Components (optional)
Use Sandpaper or an Orbital Sander to remove splinters and to smooth
surfaces of the wood.
IMPORTANT: DO NOT sand the tenons! Sanding the tenons will loosen the fit
between the tenon and hole, which can cause the joint to be weak/unstable.
2. Test-Fit Components (IMPORTANT!)
Assemble the design without glue to verify all joints fit properly.
3. Assemble Components
Apply Wood Glue to both the tenon and the hole. Assemble each joint as
outlined in the design.
IMPORTANT: Adjust joints as-needed to achieve a level, square assembly
before the glue dries. The joints will be impossible to adjust after the glue has
dried.
4. Apply Finish (optional)
Apply the finish of your choice to the assembly per the manufacturer’s
instructions. Be sure to wear appropriate Personal Protective Equipment and
to apply finish in a well ventilated area.
GETTING STARTED - ASSEMBLY TIPS
Assembly Tips
Tip
If the logs bind during assembly,
try spinning the logs to find the
best orientation for assembly.
Spin
Tip
Use a Pencil to mark the best
fitting orientation of the joints on
both the tenon side and the hole
side so these marks can be
easily re-aligned when gluing.
Mark
Tip
Keep a damp Shop
Towel handy to wipe
off any excess glue.
GLUE
GLUE
Tip
For outdoor projects, we rec-
ommend installing a single
screw through the tenon joint
in addition to glue to prevent
separation of the joint.
Install Screw

DINING CHAIR EZ PLAN
Difficulty
Intermediate
-Drilling offset holes
-Sawing boards at angle
-Joining boards
Parts List
Item
Qty
Part Name
Size
A 1 Log-A†Ø3" X 35-¾” Long
B 1 Log-B†Ø3” X 35-¾" Long
C 2 Log-C†Ø3" X 15-¼” Long
D 2 Log-D†Ø3" X 17" Long
E 1 Log-E†Ø3" X 19" Long
F 5 Log-F†Ø3" X 15-¾" Long
G 1 Board-G 1-½" X 5-½" X 20” Long
H 1 Board-H 1-½" X 5-½" X 20” Long
J 8 Screw* #8 x 2-¾” Long
*Not shown
Step 1
A. Gather all required tools and wood listed above
B. Use a ½” Single Speed Drill and Ø1-½” Forstner Bit to drill all holes in locations shown (see next
page)
C. Use a ½” Single Speed Drill and Ø1-½” Tenon Cutter to cut all tenons in locations shown (see
next page)
Special Tools Required
●Ø1-½” Tenon Cutter
●Ø1-½” Forstner Bit
Hole Size Tenon Size
n11
2in
11
4in
11
2inn
11
2in
B
A
C
F
●Ø3/32” Drill Bit
18 in
36 in
21 in 19 in
Assembly Instructions
D
E
H
G
†Landscape Timber

DINING CHAIR EZ PLAN
353
4in
4 in
151
4in
63
4in
6 in
6 in
151
4in
63
4in
6 in
6 in
4 in
353
4in
1
2in
1
2in
1
2in
1
2in
151
4in
4 in
17 in
81
2in
19 in
15
8in 153
4in
153
4in
20 in 20 in
20°
1 in
93
4in
Tip
Log-A and Log-B
are very similar.
Take special care
to mark these logs
correctly to avoid
mixing them up.
C
A B
D
E
F
G
H

DINING CHAIR EZ PLAN
Step 2
A. Apply glue to the seams of Board-G and Board-H as indicated below.
B. Lay down boards on flat level workspace.
C. Square up boards as they are shown below and secure with pipe clamps or equivalent clamping
device. Allow to dry overnight.
Step 3
A. Apply glue to the tenons and to the mating holes shown below.
B. Use Log-A, Log-C, and Log-D to build the Left Frame Assembly.
C. Use Log-B, Log-C, and Log-D to build the Right Frame Assembly.
Note: Be sure that Log-D is oriented properly when assembling both sides of the frame.
20 in
19 in
111
2in
20°
20°
11
2in
GLUE
GLUE
Left Frame
Assembly
A
D
C
GLUE
Right Frame
Assembly
B
DC
GLUE
H
G
G
H

DINING CHAIR EZ PLAN
Step 4
A. Apply glue to the tenons and to the mating holes shown below.
B. Tie together the Left Frame Assembly and the Right Frame Assembly with Log-F and Log-E as-
shown below.
IMPORTANT: Notice how the orientation of Log-F is not the same for each log, make sure they
are oriented correctly before the glue dries.
Step 5
A. Secure seat from Step 2 to chair either by
using wood screws or glue.
B. Drill four pilot holes using a Ø3/32” bit. One
hole in each corner of the seat.
C. Install the #8 x 2-¾” screws to secure.
G
H
Align logs
with flat
board
5°
F
E
GLUE
GLUE
GLUE
View A A
A

TROUBLESHOOTING
Problem Cause Solution
-Furniture does not fit
together
-Logs are too crooked -Use straighter logs
-Tenon crooked -Cut tenon straight on the logs
-Tenon too large -Adjust the tenon cutter blades to cut the tenon
smaller
-Log not oriented
correctly
-Try twisting the various logs to find the natural
“resting” orientation of each log
-Design assembled
incorrectly
-Double-check pieces and assembly with the
design in the manual. Fix any inconsistencies.
-Furniture does not sit
flat (wobbly)
-Logs are too crooked -Use straighter logs
-Legs are uneven
-Floor is uneven
-Cut or sand bottom of legs to make even
-Use shims under legs to make even
-Furniture does not
stay together
-Glue is inadequate -Use a high-quality wood glue to assemble
-Glue is not dry -Allow glue to dry completely before using
-Wood swell -Use a wood screw to hold the tenon to the
mortise for any furniture used outside, or in a
high-humidity environment
-Logs too short/too
long
-Tenon cut too
long/short
-Cut the tenon to correct length, or cut some
material off the end of the tenon
-Different diameter logs
used than plan layout
-Adjust the length of logs if different diameter
logs are used
-Top does not sit flat
-Frame not square -Adjust frame to create a square base
-Top mounting logs not
flat
-Use a table saw to cut a flat surface on the
mounting logs for the top
-Use landscape timbers for the mounting logs
-Wood splitting when
installing screws
-Pilot hole not drilled -Drill a pilot hole for the screws
-Pilot hole too small -Drill a larger pilot hole
-Screws too close to
edge
-Move screw holes further from edge of wood
-Tenon cutter “skips”
or bounces on end of
log
-Log is too large -Taper down end of log with a draw knife
-Not enough pressure
applied to cutter
-Lean into drill with body weight before turning
on drill
-Tenon cutter not
cutting log
-Blades are not
adjusted properly
-Position blades per the tenon cutter manual
(about 1/4” from the front of the blade pocket)
-Blades are dull -Sharpen or replace blades
-Drill stops while
cutting
-Incorrect drill used
(variable speed)
-Use a high-torque, single speed drill to turn the
tenon cutter at 450 rpm or less
*Log furniture is not perfectly square and symmetric like store-bought furniture. This inherent variation
is typical of all log furniture and gives each product a unique character.