Monday, August 17, 2009

material layout








I purchased about 80 board ft of cherry wood. It is all 8/4 in thickness, planned on 4 sides. This means I can start cutting the boards to size without sending them through a thickness planner. I like to buy the wood already "surfaced". I can see the grain, color and heartwood better. I like using heartwood as it gives the project some character. You need to take the time to layout all your material and decide what pieces to use. I take my templates and start making chalk lines or light pencil outlines of each piece. I can shift the templates around to cut down on waste. There will be waste, how much depends on careful use of the wood. Exotic woods are very expensive so I sometimes do a lot of erasing and rearranging of my templates. I select the best pieces for the seat, headrest and arms. These are the areas that will draw the most attention.








For this chair I decided to start on the headrest. I started on the seat the previous chair. I like to mix it up. I already know I will do the rocker and back brace strips next to get them out of the way and also to start the laminating process early as it takes 5 plus days of glueing and clamping. I only have enough clamps and forms for one glue up per day. Multiple glue ups of the laminated rockers and back braces would require additional forms. One glue up per day works as there is plenty to do on the other pieces. The headrest will require 4 pcs, 6 1/2 inches wide and 7 1/2 inches long. I cut them from the same piece as I wanted to book match the center pieces to use the heartwood edge. Start with a piece roughly 32"- 33" long and 6 1/2" wide. Cut 4 pcs 7 1/2" long. You then arrange them to get the best look. I keep heartwood to heartwood at the center. as I will do the same with the 4 seat pcs.




In the picture you see the pcs as they were cut and also the headrest template showing the inside curve of the arched headrest. The inside curve segment is 36 degrees. Not a 36 degree radius. I make my templates out of 1/4" masonite. Masonite will not dryout and warp. My templete is 23 1/4" long with a 3 3/8" rise. There is a math formula for calculating the radius but using these measurements will get you close. This is a sample of what Sam Maloof would do as far as giving you the info as he did all the calculations. I actually lost my template and had to start over using that dreaded word "math". Most people don't like math. I happen to be someone who does so it was a nice challange for me to figure it out again. Take your time in cutting templates. They will save a great deal of time if they are accurate as the jigs that you will make based on these templates to rough out the glued up headrest shape will depend on it being made with care.

I now cut the beveles on all 4 pcs. The 2 center pcs have a 9 degree bevel on each side. The outer pcs are only beveled on one edge. I label each pc starting with 1 on the left. I roughly mark the bevel direction on each pc so I don't get confused when beveling on the table saw. So looking from the top down on all the pcs as they are standing somewhat in an arc, I mark each pc and also mark the bevels. Each pc is already cut to width so I set my table saw on a 9 degree bevel and cut accordingly. I use a digital "Wixey" to set the degree. I don't depend on the saw scale as I want these pcs all exact. You can leave the square edge on the left side of pc 1 and the right side of pc 4 as they will be cut to the correct length later. Much later.........................After beveling the edges I cut biscuits into the edges (2 per pc) to help with the line up during the glue/clamp process. You don't need the biscuits or dowels for strenght but I found it helps when lining them up during clamping as you will be clamping pcs on a bevel. The glue up is a 3 step process. I first glue pcs 1 and 2 together and set them aside. I then glue pcs 3 and 4 together and set then aside. After 24 hrs, I now glue clamp strips to the 2 sections of previously joined headrest sections.






Sunday, August 2, 2009

Making a Maloof style rocking chair


This is my 1st attempt at becoming a woodworker "Blogger". I am a journeyman carpenter by trade and not afraid to tackle any and all carpentry related projects. In the past I have worked on residential homes, commercial buildings, shopping centers, condo/apartments and schools. I am at present just a woodworker doing what I really enjoy. That is, working in my shop (my garage) on projects that I pick. I would like to finish my working career as a fulltime woodworker making furniture for my family and others. I don't think I will get rich but I hope life will be a little less stressful and much more fullfilling. Thirty six years ago I built a rolltop desk. I was self taught. I thought that because I was a carpenter apprentice I could build anything because I had the tools. I was young and ambitious. I was also wrong and didn't know it. I still have the desk. It's a little crude in ways but it was an honest attempt. Some things I did right and it gave me the courage to do more. Last year I was finally able to work along side a very good furniture maker and more specifically, someone who would teach me how to build a rocking chair inspired by the ever so humble Sam Maloof. It was the best 2 weeks spent on a project. I was both excited and nervous. I knew my way around woodworking tools and machines so wasn't worried about the tool part but I didn't know the "joinery" part. I know terms like rafters, joists, decking, stucco, drywall, roach coach, porta potty, sore back etc etc. For the past few months I have been visiting woodworking forums. Places where others with the same interest can go and discuss projects or whatever. I mostly just read what others posted. A few have expressed an interest in learning how to make a Maloof style chair. They look very pleasing to the eye and to the touch. Sam Maloof passed away this past June. I was lucky enough to meet him this spring. What a wonderful person he was. I came away from his home with a very positive feeling as I discovered I was doing some of the same things Sam did. I made and sold another chair in the meantime and also entered my first chair in a woodworking competition which I am happy to report earned an Honorable Mention.


If after reading my blog you decide to build a rocking chair, then I have succeeded in doing what Sam would do and that is spreading his knowledge, tricks and time saving methods so others could learn from his mistakes and enjoy building furniture as much as he did.
This first posting took awhile so I'm calling it a day.