|Project by bigkev||posted 03-11-2012 01:23 AM||1997 views||8 times favorited||27 comments|
I started on this chair about 8 months ago and just applied the last coat of finish today. Been working too much as I suppose most of us are nowadays. I ordered templates and a DVD set from Hal Taylor and I have to say they were invaluable. Hal takes you through every step and not only shows you what to do but he explains why. I really enjoyed this project more than anything else I have built and everyone who sees it wants one. It was a bit of a challenge for me as I am not a very patient person. When I started this project my best friend of 30 years said “You’ll never finish it. You don’t have the patience for that!” Thankfully he was wrong and it turned out well. It is not perfect and has some flaws that so far only I see but overall I am very happy with it. This is a very comfortable chair to sit in and very beautiful to look at. Everyone who sees it just wants to touch it.
The second picture shows the front leg to seat Maloof style joint. I was a little intimidated by this at first but Hal’s process for this made it possible for me. This joint turned out basically perfect as did the other three. The fifth picture is of a basically assembled chair I just hadn’t attached the rockers yet. The last picture is of the Sapele that I got from a local supplier at $2.50 a board foot. I can’t wait to build the next one from some quality walnut.
It took some time to build the many jigs that are necessary to build this chair, but you only have to do that once. Hal’s video and book walks you through building the jigs. Now that I have those done and have built one, the next one should go much faster. I would guess that my total time with the jigs, construction, shaping, sanding and finishing is close to 120 hours in this chair. My Nicholson rasps and new Festool RO90DX sander with the Festool dust collector were a huge help. The smaller RO90 enabled me to get into places a larger sander just can’t.
The finish is Maloof’s mixture that I mixed myself and as mentioned above the wood is Sapele. I brought the chair up to my FROG to finish it because it is still rather cool in the garage. Thanks for looking and I welcome any comments or suggestions.
PS – I am not a professional photographer so the photos are not perfect!!
-- Kevin, South Carolina