Hal Taylor Rocking Chair #6: Back and Front Legs

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Blog entry by NY_Rocking_Chairs posted 06-05-2009 09:30 PM 4573 reads 0 times favorited 1 comment Add to Favorites Watch
« Part 5: Week 4, Leg joints and lots of sanding... Part 6 of Hal Taylor Rocking Chair series Part 7: Front leg joints and arms attached »

Seems every week there is a real life setback, this week was no exception with my wife succumbing to the head cold I had two weeks ago. She is better now.

On a shop note I have another commissioned job that is due the same time as this, so instead of having a nice 6 week buffer on the chair, I now have 6 weeks to finish the chair and complete the other project, time to kick it into high gear.

So this entry concerns the front and back legs, their shaping and gluing to the seat.

Started out today by sanding the bottom and top of the seat through to 500. Someone questioned the sanding technique last week. I came up with some more explanation. The chair is so complex when assembled that to try and sand the completed chair from 220 to 500 would be a real PIA. So I sand every piece as much as I can before assembly. There will be some re-shaping and re-sanding as assembly progresses, but those areas are limited.

Seat sanded up through 500-grit:
Seat Sanded

Last week at the end of the day I glued the adder piece (3rd front leg blank) to the two front legs that had their seat joints shaped:
Front Legs Glueup

The next step is to cut them apart. There is a front leg sweep template that lays out the outside curve of the front leg, then the two legs get bandsawn apart:
Front Legs Seperated

Using the front leg template, the shape of the leg is traced and then they go to the bandsaw again:
Front Legs Cut 1

Then a marking tool is used to mark the width of the front legs and transition curves are laid out, back to the bandsaw:
Front Leg Cut 2

Due to the weird shape of the front and back legs, they cannot go through a table mounted router easily. So a riser pyramid is built. I bought some extra inserts for my router plate and have a couple different sized pyramids that I can easily pop in and out of the router plate:
Router Jig

The front legs are then run through the router to round over all corners, followed by sanding to get rid of the band-saw lines and smooth it all out. Then set them aside.

The back legs start out by having the transition curves cut where the seat joint is, less sanding after the legs and seat are assembled:
Back leg joint rounded

Next step is to bandsaw the tops of the legs at the same angle the head rest curve will be at. This creates a smooth transition from the legs to the head rest:
Back Legs Tops

Certain corners are then run through the same round-over router jig as the front legs. Then the legs are sanded to remove band-saw lines, smooth out the transitions and cleaned up. After the rough sanding I then drill the head-rest screw holes. First a forstner bit to create a pocket for the wood plug to occupy, then the through hole. You want these to be straight so clamping in a vice on the drill press is pretty essential:
Back Legs Holes

I then sand the legs through to 500-grit and they get glued to the seat:
Back Legs Glued

Followed by the front legs getting glued to the seat:
Front Legs Glued

After this sits over night I will finish shaping the front leg joints and sand the seat and legs flush to each other. The arms will be mounted after that. After that I will start shaping the back braces for when the head rest gets finished.

-- Rich, anybody want a peanut?

1 comment so far

View jockmike2's profile


10635 posts in 4275 days

#1 posted 06-06-2009 11:39 AM

Looks like you are doing a fine job.

-- (You just have to please the man in the Mirror) Mike from Michigan -

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