|Project by bues0022||posted 02-11-2017 05:10 PM||1120 views||3 times favorited||16 comments|
I’ve been working on this chair for a VERY long time. I started it when my wife was pregnant with our first kid….6 years ago. At least I finished it a couple months before our third child though, right? Why did it take me so long? There’s a number of reasons. First, I don’t have a very well stocked, or permanently set up shop. Up here in MN, it’s awfully testing of my drive to go run the table saw in an unheated garage when it’s -10F! Also, we moved three times between the start to the end (built a house, so house projects took priority), had a couple kids, and just life in general kept me from doing much of any woodworking. It almost seemed like it would never get done, but alas I just kept on an hour here, an hour there, modifying most of the steps of the book to accommodate my tools/skills and I finally finished.
The chair is made from spalted maple and walnut – all sourced locally from two different sawmills in SE Wisconsin and Minneapolis area of MN. The seat is a 4-ply layup of walnut/maple/walnut/walnut. Backrests are maple/walnut/walnut/ash. The backrests and rockers were laminated using custom-made forms to accommodate the changes I wanted to do – such as the longer/downward curving tails to the rockers. I used the book and plans from Hal Taylor, but modified some of the features such as the curve of the headrest to mimic more of a Maloof-style. Not only is Hal’s book very instructive, but his online “support group” helps with those clarification questions that inevitably come up with something like this. It’s very easily the most comfortable wooden chair I’ve ever sat it.
I can’t even begin to count the hundreds of hours this chair took me to make. I think I have over 200 hours of hand sanding from 36 grit all the way down to 1200 grit on the entire chair. Every step of the way was stretching my woodworking abilities (I’ve never done a non-square project before), and there are some flaws that I would have liked to not have, but in the end it’s about as good as I could have imagined it ever turning out. My wife loves it and sits in it everyday – and that’s what matters most.
-- Ryan -- Delano, MN