A place for me to display some of the varied projects that come out of my shop, as well as to "talk" about some of my experiences working with wood.

Saturday, 21 July 2012

Rocker Update - Finally starting to look like a Chair!

The past while has been spent working on the rocker, I  realized I was not done building jigs and fixtures but am finally onto building the rocker. Pictures below document the process -  as always click on the pics for higher resolution.

This is a test fit of the front leg in the recess in the seat. This is an example of the precision necessary,
this piece is being held in by friction alone.An example of the level of precision
necessary to build a Maloof rocker.

This fixture takes 10" long strips and tapers them from .060" to zero.
There is a .060" strip under the right edge (opposite hinge) and runs it through the Performax.
These strips are inserted in the back braces to make the ends thicker for the tenon which goes into the chair.

Here's a stack of the wedges ready to be inserted into back brace stacks, just another task
that takes gobs of time to produce one small element for this project.

The plan called for a fair curve for the side of the chair - why not use a guitar back brace which provides
 a nice 28" radius curve which looked just dandy!
A pair of back braces in the glue-up, 24 hours like this means 4
days to glue-up the BB's for the chair.

The eight back braces removed from gluing forms and the edges cleaned up ready for trimming.

This and the next pic show a router adaptation which allows me to rout the  legs.
The glue-block on the legs makes using the table-mounter router impossible, this
riser raises the bit high enough to allow the legs to be rounded over saving a lot of shaping.

Is it safe? This bit has 7/8" embedded in the collet, providing lots of security for routing operations.
This shows the riser attached to one of the router table inserts.
Here's the front legs complete, ready for gluing, notice those big pieces around the joint, they help with clamping
and are all ground away once the legs are attached.

Okay what the hell is this Octavious Prime thing?
Yet another jig, designed to hold the legs in exactly the right position to glue
on the block which join the legs to the underside of the arms. This piece will
be shaped to blend the leg into the arm.

A long overdue shop jig, a crosscut sled, which allows me to safely do these
types of cuts on the tablesaw. This shot shows a rear leg setup to cut the joint

Rear leg glue-up, two dry-fits and 10 minutes to get everything in the right spot. No adventures
and rehearsal ensured an uneventful step. Overnight like this.
Front leg glue-up, you can see the transition pieces glued into place where the arms will go.
Overnight like this.

After about four hours of grinding and shaping, the transitions have been smoothed. Heather says
it looks like the tree grew together, following are a few closeup shots of the front legs.

Closeup of seat to front leg transition area.

Front leg again.

Front leg again from the side, notice those blocks are all gone and  it looks like a leg now.

 Lots of work done, but starting to resemble a chair!!

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