As an experienced woodworker and fabricator with over 15 years in custom furniture building, safety is non-negotiable. When using cutting tools like a metal saw that generates sparks, don full-face shield, long sleeves, and durable work gloves. Plan ahead: create a full-scale drawing with exact dimensions and angles for every chair frame part. After each cut, check pieces directly against the template for precision.
Adjust the metal cutting saw to a 45-degree angle for rear leg pieces (Image 1). Verify the cut against the full-scale layout for correct length and angle (Image 2). Repeat for all frame components, starting with longest pieces first to optimize offcuts for shorter sections.
