The joints where each leg meets the rocker need shaping to transition from a rectangular rocker to a round leg. I designed the rocker with built-up areas where each leg enters. This provided a means to make a more graceful transition.
I use two tools to shape this joint by hand. The Nicholson #49 Patternmaker’s rasp and a fishtail gouge worked great for this task. The gouge worked well to remove wood close the leg and also for initial large removal of wood. The rasp worked well to round over the edges in the transitions.
I’ve owened this rasp for over 26 years. I read a blog post that the Nicholson rasps went down in quality when they moved production to Brazil. This old model has served me well for decades. Note the aggressive tooth pattern. This is called a second-cut rasp and leaves quite a smooth surface, yet removes wood quickly.
Transitions from the legs down into the rocker. Gradual curves are pleasing to the eye.
View from another angle.
Outside view of the front leg. I plan to keep square edges on the top of the rocker. The seat has square edges at the top and the top crest will also have square edges. This will tie in all of the elements. The edges transiton smoothly from round to square.
Inside view of the front leg.
Forward view of the front leg. The lower, inside edge of the rocker is profiled with a 1/2” roundover bit over its entire length. I routed the first inch or so of the lower outside edge of the rocker with the same bit and then transitioned the edge to square with the rasp. This keeps the rocker from having an unbalanced look with a rounded edge on one side and a square edge on the other.
The rear leg has a similar transition to the front leg. Another consideration is the taper at the rear of the rocker. The top of the rocker, aft of the rear leg, is rounded instead of squared.
I still need to plug the screw holes in the leg braces. Note: When driving the plug into the forward portion of the brace, clamp the sides of the brace to keep the plug from blowing out the sides of the brace. (I learned this the hard way on a previous project!) The walls of the brace adjacent to the screw holes in the mortise are supported by the mortise.
View of the rear rocker taper.
Minor clean-up work remains over the entire lower assembly, but I’m most of the way there.
Next, I need to re-turn the 14 back spindles that I messed up earlier…
-- Mark, Florida