Saturday, April 17, 2010

Maloof Inspired Rocker, Charles Brock Plans 3

Last weekend I went over to my friends shop to use his Harbor Freight lathe, well, it had died. Apparently the motor had given up on its short, dubious quality life. Unfortunately for me I didn't know anyone else locally that has a lathe and I needed to turn the front legs for my rocker, so I did what any woodworker would do, I bought myself one, I mean, I really did need it to complete this project, really. So I went over to The WoodWhisperer's Amazon store because it really is a painless way to support a great site and to keep Marc able to keep supplying us with fantastic videos.

Once the turning was complete, and I was covered it Walnut chips, the front legs looked great in place and the chair is starting to look like a chair. Now onto the back legs, probably the most difficult part of the build so far. After creating the tapering jig that Mr. Brock describes in the book, I tapered the adder blocks on the rear legs to give the proper splay.

Then I cut the tenons on the table saw and rounded the inside corner on the router table. After a little fitting and fine tuning with my small router plane and some paring with a chisel the back legs fit nice and tight with just the right amount of splay.

With both rear legs in place and the front legs on it's really looking like a chair, tomorrow I'll drill some holes to attach the legs. Mr. Brock calls for a Miller stepped bit for the attachments of the front and rear legs, and also the headrest. I have some more cutting to do on the rear legs on the bandsaw and a little more shaping to do on the seat.
You'll notice the Rockler Bench cookies on my table, I've found these perfect for holding the coopered seat for shaping, in the DVD Mr. Brock uses what looks like a cradle custom made to hold the seat, but since I'm just making the one chair making a special jig to hold the seat seemed like overkill to me. I simply place the cookies on the table and set the seat on them, the cookies hold the seat securely when shaping and sanding. Next week, the arms, wish me luck.
"When a man is wrapped up in himself, he makes a pretty small package."
- John Ruskin

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