I decided to go with torx deck screws to replace the flathead ones I’d removed earlier.
While it seems unnecessary screws to hold the legs on if the dowels are glued properly, my expectation is that the manufacturer decided that it’s easier to mass produce chairs if you use glue and screws instead of glue and clamps.
I decided to mostly take that approach, too. I needed to use clamps to make sure things sat properly, but I used screws to hold everything in place and under pressure.
I didn’t expect to be able to rely fully on the screws to exert the same pressure as the Irwin clamps I got that exert over 300 lbs of pressure. The dowels would certainly sit properly as a result of the clamps, and the screws could take over holding them in place.
So I could switch focus to the cross pieces that have no screws to hold them in place. They’d have to dry with the clamps like normal.
With flathead/slotted screws, there’s major concern about slip-outs and head stripping. There’s nothing to keep the driver in place at high speed. With the torx deck screws, there’s no such concern.
Also it’s a good way to get rid of some dust.
With everything screwed in place, I reached for the wood filler.
And with every necessary thing patched, the next step would be light sanding and then teak oil.
More next week.