You must use a tack weld to hold the template in place while you weld the chair frame. This is crucial when making more than one chair because you want them to turn out exactly the same. A great feature on some welders is remote amperage control. Allows you to adjust the amount of heat while welding with a foot pedal.
Once the welder is in the proper position, braze one side of each joint with the filler rod. Spot welds prevent overheating and warping of the work piece until permanent welding is done. The molten metal bar fills the space between the joint creating a strong weld, hence the name filler bar.
After each weld, take a wire brush and clean the blue mark from the weld. This reduces the amount of polishing needed to remove discoloration later. When cool, take it out of the jig, turn it over and weld the other side of the joint. Repeat the process, welding the rest of the chair frame pieces together.
Use another template to position the two frame halves on the vertical template, and then place the front and rear cross members into the template channel. Using the filler rod, weld the cross members to the frames. Use a spot weld to hold them together. Clean the weld, fill it, then clean it again.
