| Project by Karson | posted 223 days ago | 287 views | 1 time favorited | 16 comments |  |
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In the interest of getting out another Toy Pattern before Christmas. I thought I’d post this before it is all completed. The weather here is 39 and finishing is not the best outside now. I’ll wait for a warmer day.
To be finished is make and put oak plugs in the screw holes, final sanding and spray finish. No! not painted.
These toys will be made for the 2008 Christmas in the Mason-Dixon Toy Workshop. I saw the pattern and decided to make 4 for this Christmas at home. Four Granddaughters each getting a doll and rocker.
Two rockers can be made from a 9” X 12 1/2” piece of wood. Minimum width would be 7 1/2” and they would be put end to end and probably take 18 – 19” of wood. The seat is 4 X 5” the back bottom is 1” X 5”. The back top is 1 1/4” X 5” Four 1/4” dowels length determined where the upper screw holes are placed.
I have a jig for holding the two sides and the seat bottom for drilling the countersink holes to screws them together.
The center box is 5” wide to hold the seat bottom at the correct angle. The screws move up and down to get the bottom at the correct angle.
The curve on the jig matches the curve on the rocker.
You clamp the two sides on and drill the countersink hole for the seat.
The back has had the dowels placed in the holes and glued.
The bottom back piece has a bevel that matches the seat angle.
The seat back is glued and placed on the seat bottom and a screw is driven through the seat into the bottom of the back.
Now the seat back is lined up with the pilot holed in the side and it is then drilled for the countersink.
And that is the assembly that I’ve done. The pieces are 3/4 for the rocker, cut with a bandsaw. sanded with a 1” X 42” sander on all outside curves and straight pieces.
This is not the one I’ve got but like the one I used. Mine is an old Craftsman that I’ve had for 40 years.
The inside curves were sanded by a Ryobi Oscillating spindle sander. Again this is not quite the model that I have but it is similar.
The front edge of the seat has a 1/8” round over router bit. The rocker sides have a 1/4” round over on both sides.
If anyone wants a paper pattern of the rocker, send me a message with your postal mail address and I’ll send one to you.
-- Karson Southern Delaware karson_morrison@bigfoot.com
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16 comments so far
David
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1801 posts in 530 days
posted 223 days ago
Karson -
Excellent! I especially like how you have your jig set up for production work.
Someone is going to be very happy this Christmas!
-- http://foldingrule.blogspot.com
Karson
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11555 posts in 791 days
posted 223 days ago
David the Jig is the Toy Workshop jig, that I pilfered to make my rockers. But it pretty ingenious. It was made by our resident jig expert who passed away last summer. We were cleaning up the shop getting ready to pass out the 2007 toys this Saturday to the charities and we kept finding jigs and saying what is this one for.
When we found this one I wrote in big letters what it was for and decided that I’d try it for this year.
-- Karson Southern Delaware karson_morrison@bigfoot.com
DAN
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2584 posts in 374 days
posted 223 days ago
Great posting. Very well done.
-- a legend in my own mind ...
rikkor
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6489 posts in 265 days
posted 222 days ago
Nice! The grandkids will love them.
-- Maplewood, MN
MsDebbieP
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10984 posts in 551 days
posted 222 days ago
oh my .. this is fantastic!
Love it
-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)
Sawdust2
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798 posts in 478 days
posted 222 days ago
Great production techniques.
Do you also have a template for routing the edges of the sides?
-- No piece is cut too short. It was meant for a smaller project.
Karson
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11555 posts in 791 days
posted 222 days ago
Sawdust2 I used a router bit with a bearing on it. The 1/4” roundover in 2/3” wood gave a nice even cut. a 3/8” bearing on 2/4 wood gives an uneven cut because the bearing on the second cut is actually riding in part of the curve cut from the other side.
-- Karson Southern Delaware karson_morrison@bigfoot.com
CharlieM1958
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3538 posts in 609 days
posted 222 days ago
Good project and tutorial, Karson. Thanks!
-- Charlie M. "Woodworking - patience = firewood"
odie
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474 posts in 231 days
posted 222 days ago
Will you really fit in that thing? This i want to see…..nice work.
-- Odie, Confucius say, "He who laughs at one's self is BUTT of joke".
Douglas Bordner
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2261 posts in 455 days
posted 222 days ago
Totally worthwhile. You guys are fantastic.
-- "Bordnerizing" perfectly good lumber for over a decade.
Grumpy
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3852 posts in 242 days
posted 222 days ago
Nice job Karson. I am sure the kids will enjoy the chairs.Thanks for the insight.
-- Grumpy - "Always look on the bright side of life"- Monty Python
SPalm
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658 posts in 273 days
posted 222 days ago
Good for you Karson. Nice to the kids, and informational to the rest of us.
I guess you like that 1” belt sander? I always wondered about them.
Thanks again,
Steve
-- Stevethepeeve -- I'm no rocket surgeon
Karson
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11555 posts in 791 days
posted 222 days ago
Those sanders are great. I’ve worn out many belts. I was buying them 100 at a time when I was making toys in St. Louis. They are the easiest tool to clean up bandsaw cuts and to make the edge 90% to the surface. They don’t work for inside circles, but they are fantastic for straight and outside curved cuts. I’ve been buying some specialized grits for the belts lately. Some Ceramic belts that are made for metal and do they have a life in wood. I buy them from Supergrit.
I’ve bought from them for years. They have a lot of discount sandpapers. I’ve also bought ROS sander replacement pads from them and also felt Velcro pads for polishing with the ROS.
-- Karson Southern Delaware karson_morrison@bigfoot.com
Bob A in NJ
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291 posts in 390 days
posted 222 days ago
Karson
Thanks for the lesson and the post. Nice work and cause!
-- Bob A in NJ
Karson
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11555 posts in 791 days
posted 222 days ago
Thanks Bob/
-- Karson Southern Delaware karson_morrison@bigfoot.com
mot
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4831 posts in 427 days
posted 219 days ago
Karson! This is a great little piece! Thanks for all the info on it’s construction. Very nice!
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)