Origami chair redesign: a plywood foundation

May 22nd, 2013 by SLSolarz

Over the next several weeks I will post photos of my rocking-chair project as it progresses.  I welcome your feedback and hope that you will help me find a name for this chair.

My design is inspired by 2 sources: the Frank Lloyd Wright Origami Chair and the Converse All Star sneaker.  I’ve always wanted to re-design the Origami Chair as an updated, cool lounger.  The Converse reference came later, after hours of observation, when it struck me (and my friend Ann who stopped by the Hack Factory for a critique session), that my placement of masking tape around the rockers was reminiscent of a pair of red sneakers (more on this in a future post).

This probably looks like a simple chair to make but there are no right angles so it was tough!

This probably looks like a simple chair to make but there are no right angles so it was tough!

A few years ago I made a large, black lacquered version of FLW’s Origami Chair and I kept one for my own home.

My original, very large version of the origami chair.

My original, very large version of the origami chair.

Using the chair at my home, I started my new chair by tracing a pattern onto poster board.  Then, I made another pattern about 2/3 the size of the large one, tweaked the proportions and used that pattern to cut the plywood.

I am interested in learning tips for sanding complicated shapes like this.  It is a slow process for me.

I am interested in learning tips for sanding complicated shapes like this. It is a slow process for me.

The seat and back are carved from spray foam and covered in body filler then sanded, more body filler, then sanded...

The seat and back are carved from spray foam and covered in body filler then sanded, more body filler, then sanded…

Once I assembled the plywood pieces I carved an ergonomic seat and back out of spray foam.  To create a smooth surface, I covered the carved foam in body filler and then did a lot of sanding.

Next week I will discuss the main design problem with FLW’s Origami Chair and whether or not I solved it.

 

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