Monday, May 24, 2010

Maloof Inspired Rocker, Charles Brock Plans 6

This weekend I got some good shop time since it was raining both days. I was able to get quite a bit done and I have to say that I'm really happy with the way this chair is looking.
I started by using the spindle pattern and marking out 7 spindles for the back of the chair. The good thing is that they are designed so that you can cut them out like nesting spoons, thus saving alot of wood. After bandsawing four from one board and three from another I cleaned up the cut marks on the spindle sander, how appropriate.

Next I took a posterboard cutout of the front profile of the spindles and transfered the marks to both sides of the spindles. I then took the stock back to the bandsaw and again to the spindle sander. Once everything was cleaned up and shaped correctly I marked a centerline on the front and back to aid in shaping and lines on the side to help me maintain the right shape. With a spindle resting on the table I used a roundover bit in my small router to shape the long top taper of the spindle. I then mounted the spindle in the vice and shaped a slight round on the front and a steep round on the back with the microplane, I also shaped a round on the short bottom taper.

After sanding each spindle with 60 grit on my random orbit sander I marked each to length and shaped the bottom with a 1/2 inch tapered dowel cutter and the top with a 3/8th inch tapered dowel cutter both of which Mr. Brock recommends in the DVD. With each spindle shaped and tapered I proceeded to sand them 80, 120, 180, and 220 grits.

With the spindles completed I sanded to headrest up to 220 grit and I sanded the inside of the back legs through 220 grit. After placing the spindles in place I attempted to fit the headrest but had to take it off a couple of times and trim and adjust a few of the spindles. Once everything was adjusted and fitted correctly I was able to screw the headrest in place. At this point I noticed that a couple of the spindles that had cut outs that did not exactly line up, so I marked the cut outs that needed to be adjusted and called it a weekend. Next weekend I plan on cutting the stock for the rockers and laminating them. At this point I cannot wait to start oiling this chair up and seeing the grain come to life.
"We are what we pretend to be, so we must be careful what we pretend to be."
- Kurt Vonnegut


Tico said...

It's looking great!

Vic Hubbard said...

It's going very well, Brad. Do you think this is your most ambitious piece yet?