|Project by Charles Brock||posted 10-20-2012 12:46 PM||2030 views||8 times favorited||18 comments|
I have always wanted to take the Maloof style Low Back Chair and try my hand at doubling it to make a settee. Here is my first in curly walnut. One of the interesting aspects of the project is the obvious question of support for the long seat. A middle leg just ruins this piece and Sam Maloof was able to build his without it. I like a challenge! Using Festool Dominos, I am able add support (And Align) all nine boards that make up the seat. I don’t think biscuits would work to give it enough strength. The real support comes from the massive piece of burled black walnut I cut from a slab (2 3/4” thick) to make the low backrest. I use a the larger Festool Circular Saw and a guide rail to plunge into the slab and cut out the piece I want with the desired grain orientation and figure. It is really a stretcher and helps the seat resist collapse. It was absolutely fun and challenging to sculpt. I start shaping with 24 grit sandpaper and go all the way through 1000 grit (white Scotchbrite pad) with my sanding schedule. The shaping continues with the grinder, a Foredom Industrial flex shaft grinder, Auriou rasps and a multitude of scrapers. This is takes a lot of time to get it to flow. The finish is Masterpiece Wood Finish a three Part Oil and Wax Finish that I developed with a coatings expert for my projects.
I will be at WIA 2012 MidWest (NorthernKentucky Convention Center / November 2 & 3) if you would like to see this piece.
-- Charles Brock