The saga continues …
And more lessons were learned from the v2 chair.
With the extra height, and therefore extra flex, one of those chairs broke a leg (not in a ‘going on stage’ kind of way).
We pulled off a really quick fix replacing the affected leg with one that had small brace piece screwed into it. So far not broken.
Here’s the cut part way through. Some components have already been completely cut off the board and removed. They’re double layer, so require some time for the glue to properly set up.
There were some glitches in the cut. I took a record of all the dimensions, but I’ve only done a limited analysis so far, certainly haven’t yet figured out the most likely cause, although I do have an idea.
This is the completed chair. No elongated back legs, and the front legs are braced, as described above.
It’s not a one-handed trick to open or close the chair like it was with v2, but it can do a new party trick instead. And stand upright when folded 
It’s also lighter, at around 20kg (multiply by 2.2 for those other units), and much easier to handle. I would consider it a ‘one-person-luggable’ design now.
This is the design we’re going into production with:
29 back assemblies completed.