Here are the frames for the lower arms.
I had to put a string on the inside of the lower arm so I could pull the recline switch wiring through after everything was upholstered.
And here is the stack of lower arms.
Next I needed to cut the notches of the stringers that will space the arms when everything is finally assembled.
Some of the lower arms have both sides cut, and some of them only have one side cut depending on were they will be mounted in the end.
Next I had to cut the hole for the cupholder in the upper arm.
The cupholder fits just fine!
The seat rack is mounted to the arms with four 1/4" lag bolts. The rack has notches so you can pre install the bolts and just drop the rack in place. I'm using 3" long lag bolts and the spacers are there to let me pad the inside of the arm without causing too much interference between the arm and the seat bottom.
Next I needed to assemble a single chair to test for function and interference. Here are a pair of arms with the stringers mounted and feet attached.
And here are the upper arms attached to the test setup.
The seat rack fits like it should.
Here is a piece of 4" thick foam on a 3/4" board over the seat rack. This will be roughly the finished height of the seat.
Here is the footrest extended.
The next step is to get the back shaped correctly. Once that is done I can make all the parts for the footrests and the seat bottom.