Not a full build, but still an interesting challenge. Client has a Marlowe Ceccotti office chair, made out of cherry. The legs kept snapping off, even after being repaired. As it turns out, the issue was due to bad hardware design: the brass caps for the casters were notched into the legs in a way that basically started a split that was almost unavoidable.
The original manufacturer tried solving the problem with plywood splines, but when the chair came my way, it was clear that their solution wasn't working. So, I redesigned the way the legs were reinforced, shaped the replacement legs to match the original design, and refinished the chair.