Lets build a Sam Maloof style rocking chair! If you want to follow along with your own text, go to my web page.
I would like to explain that I am a woodworker with over 60 years of experience. The following information is good for woodworkers and all that you will need. This info is not intended as a fancy demonstration of drafting or book making. The text is detailed and complete with pictures, but little effort has been given to dress up the presentation with fancy foot work like blue print drawings or commercial pictures and printing. Everything you need is here to make a custom rocking chair. What else would you want?
Copyright material, written permission from Bill Kappel is required for reproduction or commercial use of any part of this information.
How to build a Custom Sculptured rocking chair
Word of warning: I may sadly through ignorance, error, foolishness or carelessness advance various notions, which could lead to some undesirable health risk or accident. You who make the choice to follow these instructions are reminded that as free independent individuals you are responsible to appraise yourselves of ALL applicable safety precautions. If you choose to proceed with these instructions be advised I cannot be held responsible for your safety.
I will take you through a complete detailed instruction of how to build a custom sculptured rocking chair. The instructions will cover every aspect of construction, as well as materials, tools, jigs, techniques, secrets of the trade, little known methods, short cuts, pictures and anything else helpful.
Because some may be novices I will give the reasoning along with the procedure for many of the undertakings.
When I make a mistake in grammar, spelling, syntax, punctuation or other clues to my English ignorance please forgive me. If I make a mistake in woodworking please correct me.
I am a self-taught woodworker so some of the techniques I use may not be familiar to you. My terminology will be close and descriptive, but not always what you may be familiar with using. I have been woodworking for over 60 years and still have all my fingers and never have I had a serious accident. So I do know a little something about the subject I will be discussing. I do know how to make, what I think are the finest rocking chairs ever made, the right way that will last much longer than any of us will live. In most cases I use the 'Old World Masters' way of doing things, but I do not use them to the detriment of time, material or energy. If I can do a job with less work, in less time, having the same or better outcome, I will use it without hesitation.
There is no desire to take any shortcuts in explanation or procedures. You will find the smallest detail discussed which is often the pertinent thing left out of commercial books, that makes a master work piece stand apart from the ordinary.
We will go through the same construction procedure I use for one of my rockers in the same sequence of manufacturing. A detail of how to upgrade or modify a particular unit of the rocker to what I think is an improvement or enhancement for attractiveness or functionally will be explained.
Lots of pictures are added to help in understanding or visualizing particular aspects of the manufacturing process.
An introduction into the philosophy of what makes a rocking chair unique among chairs is helpful. Also how to choose a rocker adds insight which is useful especially when making choices during design junctures.
Learning the "Dynamics of a Rocking Chair" is crucial to our beginning:
Dynamics of a Rocking Chair
by
Bill Kappel
Unlike most chairs, rocking chairs by their very nature of construction are a moving entity. Because a rocking chair is made to rock there are unique factors to be considered in the manufacturing of a custom quality rocking chair. First, let us agree on some basics. The design or style of the rocking chair is pleasing, the materials used in construction are quality products and the method of construction is proven and time-honored mechanics. With these basics assured, let us examine the real reason why one rocking chair is a pleasant experience while others are adequate at best to exasperating.
An exasperating rocking chair would be one that walks while rocking or a "walking rocker". Walking while rocking is an irritating experience some rocking chairs exhibit by advancing forward or backwards, maybe sideways, off their original placement, during the rocking action.
Another exasperating characteristic of some rocking chairs is their persistence in giving the sensation of throwing you forward out of the chair or too far backwards.
An adequate experience in rocking can be measured collectively by most rocking chairs on the market today. They feel okay, nice, comfortable, or sufficient, but this should not be what a quality buyer is obliged to tolerate, however, this is what most people settles for; a cookie cutter rocker.
There is another category that I call "balanced rocking" a sooo comfortable and good feeling experience of a perfect balanced rocking chair. This is the exceptional rocking chair that is of course sized correctly with proper ergonomics, but it is also engineered to give the ultimate rocking experience, which is perfect balance so that the rocking is almost effortless. Near effortless rocking is what I design into my rocking chairs. How is this done?
Sizing a chair to fit a particular individual or category of body types such as standard, small or petite, large or ample, is important, but lets face it almost anyone can sit in a chair. I am six foot three at two hundred and fifty pounds and I am quite comfortable in a petite, standard or large size. So what is important to a rocking chair?
There are several important considerations when building fine rocking chairs with the above given qualifiers.
One,
The size of the rocking chair must be within the reasonable range of the owner and guests. Size is important as to width of the seat, the armrest placement and design, the seat clearance from the floor and the height of the headrest, etc. Once these dimensions are accurate the builder can calculate the other subtle proportions.
Two,
It is also important to consider that the head should have adequate support while relaxing. On an airplane when you want to rest one of the first things you do is ask for a pillow. Why a pillow? To give support to your head and bring it forward a little for more comfort. Many people while rocking come close to sleeping or total relaxing. To get this fully relaxed feeling your head should be supported and not thrown back beyond comfort.
Three,
Back supports with contour considerations are paramount objectives. A specially designed Backslat can add much pleasure to the rocking experience.
Four,
The arms of a rocking chair allow considerable latitude for design, but if one is realistic it must be considered that a well-designed arm will give comfort rather than adaptation to a style.
Five,
Style or appearance of the furniture should be pleasing. The look of the rocking chair is, of necessity, controlled by the function of rocking, but this still leaves room for variation and individual taste.
Six,
To my mind, the most critical characteristic of a rocking chair is balance. Balance is why you buy a rocking chair. After all, if we weren't interested in rocking then a regular chair would do just fine. Rocking should not be tiresome to the occupant even after prolonged periods of rocking. Rocking should be almost effortless. Rocking should be a pleasant and a relaxing experience. To achieve this perfect balance of relaxed rocking the builder woodworker must have mastered certain dynamics about a rocking chair design. The "runner" is the part of a rocking chair that controls the movement of force applied. These "runners" must be made to match the dynamic uniqueness of each rocking chair.
Wood is never of a uniform density. Because the density of different woods varies from species to species, as well as within their own species, the woodworker must consider the balance point of each rocking chair made and shape the "runners" accordingly. A production "runner" manufactured in a high volume plant or one made on a jig in a one-man shop will not give the perfect balance for a quality rocking chair. If a standard "runner" is used the resulting rocking chair will only be of adequate quality, at best, and not the superior balance that a high-end rocking chair owner should demand.
Making chairs is the most challenging of all woodworking projects and making rocking chairs, the correct way, is the supreme challenge in woodworking.
Each of the custom rocking chairs built by Bill Kappel is constructed with this perfect balance or dynamics of the rocking chair in mind. Each rocking chair is balanced for the customer for an almost effortless rocking. No rocking walking or undue effort to annoy and distract from the pleasant experience of a well tuned rocking chair.
The next step in "How to build a rocking chair" is learning--How to select a rocking chair
First, be sure the back braces are sturdy and do not move. A flexible back brace will fail at the wood-to-wood contact point. If wood moves on wood it will wear away wood at this point and eventually fail. Considering the several methods of the 'Backslat' construction the rigid slat is as pleasing to ones back without the complications of extermination and wood failure. I looked into this method of construction and decided if the rigid slat was good enough for Sam Maloof it is good enough for me besides I rejected the movable slat because it is unsound engineering. If you plan on having an heirloom rocking chair a flexible back slat will at some time become a crucial problem.
Next, the headrest or Headcrest is more comfortable if it supports the head. On an airplane if one wants to rest one usually ask for a pillow because our bodies are more relaxed with the head supported a bit and not thrown back in an uncomfortable position. The same holds true for a rocking chair that is why I make my Crown style rockers with this head support. Sometimes I do make a sweeping curve for the headrest (classic) to comply with existing furniture.
Another point to consider is the armrest. The armrest should be shaped in such a way so it will support the arm without cutting the circulation in the forearm. Many armrest styles have a hard inside edge that puts pressure on the forearm and cuts circulation if you rest your hands in your lap. My armrest (Sam Maloof style) is shaped to allow the hands to comfortably rest in the lap while the arms are supported at the elbow without an uncomfortable hard inside edge.
One of the choice features of a quality rocking chair is perfect balance. A rocking chair is a moving entity and special care must be taken to insure comfort at all stages in the rocking action. This balance feature is only achieved by years of experience and sound design modifications on each custom rocking chair made. Each rocking chair must be handmade to adjust for the density of wood used and design features adaptable to each patron. If a new mother and child is a major consideration, be sure the rocking chair has an ample seat size to accommodate mother, baby, pillow, blankets and reading material. Also, if the occupant would like to just curl up with a leg on the seat to read or daydream, as my daughters do, then this larger seat size is more comfortable. My reader rocker is made just for such an occasion. You can view the Reader Rocker on my web site under the gallery button.
With all this propaganda out of the way we can start looking at 'how to build a custom rocking chair'.