I started with a the same concrete molds that I used before for the two leg cast.
Previously, Tim mentioned that the concrete was too white which is a sign that the concrete either dried way to quick or there wasn’t enough water in the mix. The problem was that the foam itself sucked out the water through capillary action. To fix this problem i sprayed about 5 coats of shellac so that the pours of the foam mold would be covered. I then proceeded to cast.
I strained the aggregates once again. Same process and explanation as before.
The casting process took about 3 hours.
I positioned filled rods at the correct positions so that the holes would be pre-made into the concrete cast.
I then extracted the cast. I extracted it early so that the concrete would dry faster. This was a major risk but I had to do it in order to finish the project on time. I only waited 2 days before extraction.
The cast was a full on success!! I waited an additional two days and then I sanded the concrete with 80 grit sandpaper to get clean and get rid of the jagged edges.
The holes method worked out as well. (1H)
I then created all of the CNC components. This took the longest. I had to model the chair, make the file for CNC milling and then preform the actual mill. I also had to sand the pieces so that the edges would not be sharp. (Note not the round portions)
These are all of the pieces that were required to make the chair. The total CNC process including milling and setting up was about 6H.
I then started assembling the chair. I used 3/8″ threaded rods and lock nuts to assemble the entire chair. No glue was used at all. The rods had to be cut to the correct size. Assembling the chair was no easy task. (6H)
The build was a success! After many hours later of course. I am very happy with the results. 
TOTAL TIME 16H-18H
TOTAL COST $100
