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The upholstered chair cushions for the dining chairs use a 3/4” Birch plywood insert as a platform. To cut the 3/4" Birch plywood to a more manageable size, I used the Ridgid OCTANE 18V 7-1/4 in. Circular Saw. This was the first time I've ever used a battery powered circular saw. I was quite impressed by the power. The Ridgid OCTANE Circular Saw provided a dust collection port. I attached my favorite Ridgid shop vacuum but I was not impressed with the dust collection. I'm sure it collected some of the dust but I'm used to plunge saws that collect much more dust when attached to a dust extractor. However, the convenience of a battery powered circular saw greatly outweighs the lack of dust collection.
Next, I crosscut the plywood to final width on my table saw and crosscut sled.
I had already developed a template to fit within the chair rails. So I traced the outline of my template on all the chair insert blanks. I like to use a Sharpie marker because it gives me a margin of error when I’m rough cutting on the bandsaw.
The chair inserts are rough cut on the bandsaw. I use some thin double stick tape to temporarily attach the template onto the plywood insert blanks. I used a pattern router bit on the router table to get a perfect match.
The bottom edge of the chair insert get a 1/8” round over to ensure the upholstery fabric doesn’t rip along the edge. The top edge of the chair insert get a 1/2” round over to help shape the 2” upholstery foam.
To allow for air within the 2” upholstery foam to escape, a 1” hole was drilled towards the rear of the chair insert.
I ended up adding a 1/8” round over to the 1” hole to prevent the upholstery foam from getting cut along the edge.