Below is a brief description of the chair-making process. For more information, read the article about Lucky Acorn Chairs from the Woodworker's Journal.

He uses a traditional chairmaking technique called greenwood joinery, which interlocks green post to dry rung mortise and tenon, adding strength and longevity to the chair, in combination with modern tools and techniques, which contribute precision and speed without compromising quality.

Click on a part of the chair to see how it's made.

Finial

The elegant acorn finials add the final touch that makes the chair a joy to behold.

Slat

The slats are steam bent. Using heat and water, the wood is made flexible enough to bend into a comfortable contour. Placed in a rack to dry, the slats retain their new shape. When assembling a chair, the slats are selected for color and grain and matched for each chair. Wooden pegs are used to fasten the slats to the back legs.

Leg

The legs are hand-turned on the lathe without the use of duplicators or steady rests. The skill of the turner is the only quality control. The wood is air-dried to maintain a moisture content higher than that of the oven-dried rungs. After assembly the legs shrink around the rungs.

Arm

Bandsawn from solid pieces of wood, the arms are contoured to comfortably fit your arms. Under the arm is branded the Lucky Acorn logo, with the signature of the artist and the year.

Seat

The hand woven seats are available in split hickory bark, or Shaker tape in a variety of colors. Hickory bark is a tough and resilient material used in traditional chair bottoming. By far the most durable, it is stripped from logs in the spring. The outer bark is removed and the inner bark or phloem layer is hand-split and woven into seats. Proper care consists of wiping occasionally with a damp cloth. This seat will last 40 to 60 years. Shaker tape is a tightly woven cotton fabric. Durable and strong, it provides a soft and lasting seat. With care Shaker tape will last 20 to 40 years. Colors available upon request.

Rung

Green wood joinery is used to build these chairs. The rungs are oven dried to shrink them and remove as much moisture as possible. While in this dry state, the tenons on the end are cut and glued into the mortice on the legs. The legs being of a higher moisture content shrink around the tenons creating a stronger longer lasting joint.

Rocker

Bandsawn from a solid piece of wood, the rocker is curved for a smooth, easy feel. They are fastened to the legs with wooden pegs that are removable to allow disassembling of the rockers for easy storage and shipping.

Still intrigued? Check out the article from the Woodworker's Journal.