Step 4: Cut the Notches

cutting the notch for the front leg of a Westport chair with a jigsaw
Photo: Wendell T. Webber
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Use a jigsaw to cut the short lines straight into the board, as shown, but don't saw past the longer cutline parallel to the board's edge. Use a drill/driver to bore a ⅜-inch hole through the board's face in a corner of the notch's waste area. Tilt the jigsaw's shoe to 12 degrees, and insert the blade into the hole with its angle matching that of the beveled edge. Complete the notch by bevel-cutting along the long line. Mark and notch the other front leg to mirror the first.
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    Tools List

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    • miter saw
      Sliding compound miter saw to crosscut the boards to length
    • adjustable clamp
      Clamps to hold the parts together during assembly
    • circular saw
      Circular saw to cut the parts to width
    • framing square
      Framing square and combination square for marking cutlines
    • jigsaw
      Jigsaw to cut notches and curves
    • drill
      Drill/driver
    • hand plane
      Hand plane to straighten board edges
    • sandpaper
      120-grit sandpaper
    • sanding block
      Sanding block
    • pencil compass
      Compass
    • torpedo level
      Torpedo level
    • 3-inch wide paint brush
      3-inch paintbrush to apply teak oil

    Shopping List

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    ½ x 10 cedar boards.
    Get four 8-foot lengths

    1 ⅝-inch stainless-steel trim-head screws

    Teak oil to finish the chair