03-02-2011, 08:09 PM
As you may recall, I built a rocking chair for my father-in-law and gave it to him last year for his retirement and said that my next big project was a Hal Taylor inspired rocking chair. Well, the time has come that I really need to make some progress on the new rocking chair if there is any hope for me to get it finished by June and surprise my wife with it on our 10th wedding anniversary. Therefore, I have decided to do this build along thread to keep me motivated, to keep me on track, and to keep me accountable!
After deciding that this was the project I wanted to tackle, I ordered the plans and the DVD’s and anxiously awaited their arrival. Within the first 3 or 4 days after receiving them, I read through the plans and watched all three DVD’s (about 10 hours worth of videos). I also did some research online and tried to formulate my game plan. I made several of the recommended and/or required jigs and thought I was off to a pretty good start. I started all of this in May of last year, giving myself over a year to get this finished. Well, as usual, other projects, events, and activities popped up (including a full bathroom remodel that took up most of December and January), so the rocking chair project was put on hold….until now. Since I recently finished another project that lingered around for way too long (rocking motorcycle), it’s now time to focus on the rocking chair.
I ordered the full-sized templates and the BBHT (back brace hole template) a few weeks ago and am acquiring the necessary/recommended tools. I purchased the Kutzall grinding disc and got it in the mail a couple of days ago, received the Makita grinder yesterday, and got the rabbeting bit today. I know there are a few other items I’ll need, but I’m trying to purchase them only when I am ready for them and therefore going a little easier on my tool fund….which is almost non-existent at this time.
To add a little bit of sentimental value to the chair, I am building it out of some spalted maple that came from a tree that was in our yard. The tree, unfortunately, had to be removed when we had some septic work done and I couldn’t bear to have it cut up into fire wood. Though it wasn’t an ideal tree/log to have milled, I found a local guy with a woomizer and kiln that was able to cut and dry it for a pretty reasonable rate. While it took him a while to finally get the logs milled and dried, it actually turned out good for me because the wood has some really nice spalting throughout, but is still very solid.
Below are some pictures of the jigs, fixtures, templates, and chair parts I have made as of March 1, 2011. I will try my best to keep this thread updated and the project moving along, but I may need some friendly persuasion and reminders along the way!
Thanks,
-jason
________________________________
First up are the templates, jigs, and fixtures!
[b]Rocker bending form: 2 pieces of 1 1/8” thick MDF glued together, cut, shaped, and sanded, still need to drill the holes and attach the angle iron/aluminum.
Back brace form: 2 pieces of 1 1/8” thick MDF glued together, cut, shaped, still need to drill the holes and attach the angle iron/aluminum.
Front leg notch routing fixture:
Head rest angle jointing jig (4 degree): I added a little block to the back of this to help in “pushing” the piece through the jointer, it’s shown in the pictures below.
Arm Rest Shaping fixture:
Arm rest template: ¾” MDF
Rocker tail and Front Leg templates: ¾” MDF
Six degree Jig for cutting the seat pad on the back leg and for trimming the headrest to fit
The following are the parts of the rocking chair I have worked on so far…
Seat – two piece glue up, front and rear leg notches cut out, back brace holes drawn in
Head rest – six pieces cut to size and glued up
Arm blanks: Cut to rough size, but not shape
The last few pictures are a couple of bookmatched pieces of 8/4 spalted maple lumber that I am planning on using for the back slats and possibly the front and back legs.
After deciding that this was the project I wanted to tackle, I ordered the plans and the DVD’s and anxiously awaited their arrival. Within the first 3 or 4 days after receiving them, I read through the plans and watched all three DVD’s (about 10 hours worth of videos). I also did some research online and tried to formulate my game plan. I made several of the recommended and/or required jigs and thought I was off to a pretty good start. I started all of this in May of last year, giving myself over a year to get this finished. Well, as usual, other projects, events, and activities popped up (including a full bathroom remodel that took up most of December and January), so the rocking chair project was put on hold….until now. Since I recently finished another project that lingered around for way too long (rocking motorcycle), it’s now time to focus on the rocking chair.
I ordered the full-sized templates and the BBHT (back brace hole template) a few weeks ago and am acquiring the necessary/recommended tools. I purchased the Kutzall grinding disc and got it in the mail a couple of days ago, received the Makita grinder yesterday, and got the rabbeting bit today. I know there are a few other items I’ll need, but I’m trying to purchase them only when I am ready for them and therefore going a little easier on my tool fund….which is almost non-existent at this time.
To add a little bit of sentimental value to the chair, I am building it out of some spalted maple that came from a tree that was in our yard. The tree, unfortunately, had to be removed when we had some septic work done and I couldn’t bear to have it cut up into fire wood. Though it wasn’t an ideal tree/log to have milled, I found a local guy with a woomizer and kiln that was able to cut and dry it for a pretty reasonable rate. While it took him a while to finally get the logs milled and dried, it actually turned out good for me because the wood has some really nice spalting throughout, but is still very solid.
Below are some pictures of the jigs, fixtures, templates, and chair parts I have made as of March 1, 2011. I will try my best to keep this thread updated and the project moving along, but I may need some friendly persuasion and reminders along the way!
Thanks,
-jason
________________________________
First up are the templates, jigs, and fixtures!
[b]Rocker bending form: 2 pieces of 1 1/8” thick MDF glued together, cut, shaped, and sanded, still need to drill the holes and attach the angle iron/aluminum.
Back brace form: 2 pieces of 1 1/8” thick MDF glued together, cut, shaped, still need to drill the holes and attach the angle iron/aluminum.
Front leg notch routing fixture:
Head rest angle jointing jig (4 degree): I added a little block to the back of this to help in “pushing” the piece through the jointer, it’s shown in the pictures below.
Arm Rest Shaping fixture:
Arm rest template: ¾” MDF
Rocker tail and Front Leg templates: ¾” MDF
Six degree Jig for cutting the seat pad on the back leg and for trimming the headrest to fit
The following are the parts of the rocking chair I have worked on so far…
Seat – two piece glue up, front and rear leg notches cut out, back brace holes drawn in
Head rest – six pieces cut to size and glued up
Arm blanks: Cut to rough size, but not shape
The last few pictures are a couple of bookmatched pieces of 8/4 spalted maple lumber that I am planning on using for the back slats and possibly the front and back legs.
