In the last post you saw my fancy-schmancy headrest cutting jig. Well, I couldn’t come up with any reasons not to use it, so I loaded up my one and only headrest blank, fired up the saw, and started cutting… Here you see the back side of the headrest after the first cut. As you can see, the blade blew out the back side as I went along, but I figured I could sand it out… It’s a bit hard to see, but this picture shows the blade position just after exiting...
Hey team,I’ve behind in my project updates, so I’ll try to put up a few short posts covering what I’ve done in the last few weeks. With front and rear legs attached to the chair seat, it’s time to cut out the curved headrest. If you remember, I glued up 6 pieces 8” tall with a 5 degree bevel on the edges to create a arc of wood. We want the finished headrest to be a smooth curve front and back on a 28.5 inch radius. Naturally, I built a jig: In...
We’ve all been there: you do the dry fit, you set up your clamps and cauls, you clamp it up dry, you remake your cauls and clamping blocks. Then you do it again. Then one more time, just to make sure. You clear everything from the area but the tools and parts you need. You go through the steps in your mind for the 20th time. Then you open the glue, and it all goes to sh!t… If you’ve been following along, you know I’ve spent the last two months building this roc...
My daughter is pregnant and I though I surprise her with a rocker for her first born. The rocker will be made of leopardwood and walnut. I got 8/4 ash for the laminate forms. I’ll have about 6 hours a week to work on it so it will take most of the winter. I haven’t ever made a rocker so I bought the plans from Hal Taylor and I’m already glad I didn’t try it on my own. Day oneI bought some 1/2” baltic birch for the chair patterns, cut them on the bands...
I just sent an email off to Hal asking questions on some of my progress, and I realized I had taken some pics that I had not posted. I built a jig to cove the arms; it is designed to hold the arm billets in place with three threaded rods, and to hold the jig at an angle to the saw blade. Here are pics: This shows the jig in action on the table saw. The square frame holds the billet in place with three rods. the rods are epoxyed into wood handles and run through threaded inserts screwed...
I threw caution to the wind and took my new Kutzall to my seat. Most of this is by eye, which is a leap of faith for me, but I think it might turn out ok in the end. I strongly suggest doing all of this work outside! I moved in later when the sun was on me and now my shop is covered in dust. I felt I had one “good” side, and one less good, so I made a template of the good side and transferred the shape to the other side. And I saved the template… Much san...
The headrest is made up of 6 billets, 4.75 wide by 8 tall. They are glued together to form a curve. This means they need an angled edge to create this curve. I used a Wixey angle guage to make a pair of coopering jigs for the jointer. They are 4 and 5 degrees. Using the cut offs from the jig I glued up pairs of billets: With three pairs of billets glued up, they were too curved to clamp together so I used pinch dogs top and bottom. These worked great. Finished, they ...
Hey gang! It’s been a while, but I’m back in the shop making scrap and creating a ton of dust. Over the years I’ve made bookcases and tables galore, all with straight lines and square corners. Then I started making some G+G pieces with rounded edges, cloud lifts, and ‘pillowed’ plugs. I’ve been wanting to continue this progression and make something with no straight lines at all: a Maloof-style rocking chair following the steps from Hal Taylor. Today...
In this time lapse video I am gluing up 4 flexible back braces for a custom wooden rocking chair. A back brace is built using 4 layers each layer being about 2.2mm thick, the top or front layer is Birdseye Maple the rest are Walnut. This chair will be Black Canadian Walnut thus the the Birdseye Maple will give a attractive and interesting contrast to the rest of the chair. We make sure to cut the fronts and backs from a single piece and keep everything in order so in the end we have a beautif...
What makes Sam Maloof’s work so attractive at first glance? When I saw my first picture of his rocker in the old 1983 article in Fine Woodworking, What jumped out at me and said, “Wow”? What inspired all that has been said and done by woodworkers and lovers of fine furniture based on that initial look at his rocker? Maloof was a master woodworker, designer, finisher, personality and other things wonderful but my thought is to capture all of us so totally with that first g...
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