Repairing a broken chair leg
The chairs originally cost around $400 each. So it's definitely worth fixing.
The reason the chair leg broke was that the grain was a bit crooked. The line on the picture at left shows the direction of the original boards, as can be seen by a faint glue line just above the line on the picture. With the curly grain on this piece, the grain direction deviated quite a bit from the board direction, and with the leg at an angle from the board direction, the grain was at quite an angle compared to the leg.
Thanks to the curly grain in this piece, lining up and gluing the pieces was easy. And with the glue as strong as the wood, just gluing it on makes it good as new. But with the grain crooked as it is, good as new really isn't very good.
So I cut some channels into the legs to inlay some wood with the grain parallel to the leg. I used a slot cutting bit on a palm-sized router. A router with a bigger base would have been better for some of these cuts, but the base would have prevented me from getting close enough in a few spots.
I hate using a router like that. Sawdust thrown straight at me. Ugh!
I then measured the depth of the groove, added half a millimeter, and scored a line at the right distance parallel to the curve, and then cut to the line. This gives me the inside curve. For the ends, I used a 1 1/4" (30 mm) washer (same diameter as my router bit) to mark a radius, which I then also cut on the bandsaw.
I clamped the chair's leg in my vise. Hmm, if I clamp a leg in a vise, does that make it a leg vise? I can however say that a swiveling metal vise like this one is much handier for this application than a traditional workbench leg vise would be!
With careful work, it's possible to flush trim the wood with a chisel without damaging the surrounding finish — except the spot (near my ring finger) where I slipped with the router and gouged the wood.
Furniture repair isn't that fun or creative, but it's one of the most effective things, in terms of saving money, that you can do in a small home workshop.
Another method of
fixing chair legs
Another chair repair
Making kitchen chairs
Cracked cabinet door repair (video only)