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Ajcoholic
01-30-2014, 08:28 PM
So, in January 2012, just before I bought my SHopbot router (took delivery mid February 2012) I built a Maloof rocker out of walnut. I built it for myself, but had it displayed at a local trade show and I was made an offer, so I sold it.

Ever since I bought my Buddy BT48 Alpha, I have been busy making chairs (one of the main reasons I bought a CNC router). I have also wanted to build another rocker... for myself.

I recently got my hands on some very nice 8/4 figured maple. I decided to get another rocker done before the end of April - you got it, for the next home & trade show.

The first step was to rough cut the seat shape, and carve the saddle shape. The "old school" way (with shaves and chisels) took me 6 hours to hand carve a seat - using templates and other measurement tools to keep everything symmetrical.

Today, it tool me between 10 and 15 minutes in Aspire to draw up the seat, create the cut file - and 47 minutes to cut it out. I used my trusty Onsrud 5/8" solid carbide ball end spiral, 10,000 rpm - 3% stepover and 400 ipm feed. With just a hair over 1/64" stepover, there is almost no machine marks left to sand out. Sweet! And it is perfectly symmetrical. This is too easy...

The legs and crest rail I have rough cut the material for - I plan to use the CNC for more shaping on some of the parts. Will post more as I get to it - in between other jobs. Currently I have two medium sized custom wood kitchens, some interior doors, 3 mantles, & a dining table on the go (at the same time!)
But if I take 1/2 hour here and there, over the course of several weeks I'll get it done.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1589_zps80822079.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1589_zps80822079.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1594_zps8c478643.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1594_zps8c478643.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1598_zpse2462bb0.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1598_zpse2462bb0.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1593_zps24439b60.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1593_zps24439b60.jpg.html)

bobmoore
01-30-2014, 09:50 PM
It is always a treat to read your posts Andrew. Thanks Bob

Brian Harnett
01-31-2014, 06:07 AM
Looking forward to the finished product.

scottp55
01-31-2014, 07:46 AM
Andrew, Had to look up Maloof. That style is a favorite of mine, but never knew it had a name. Maybe if you put a price tag of $18,000 like his "Think or Thwim" chair you'd get to keep this one:) Are your rockers going to be a deep V, or more Parallel? Beautiful wood and work.

bleeth
01-31-2014, 11:44 AM
Scott: Sam Maloof was one of the greats. Do some research and find the spread on his house-It's outrageous. His furniture wax is terrific. They likely still sell it at Rockler. JFK's Rocker was a Maloof. His writings are terrific.
Another great that is worth reading is James Krenov, particularly his Cabinetmakers Notebook.. He has a unique approach to woodworking that I think you would particularly appreciate.

scottp55
01-31-2014, 12:41 PM
Yep, Got Krenov's books when I first started wood and got me into hand tools and mindset. Greene Brothers and Gustav Stickley my other icons. Don't know how I missed Maloof. Disdainful of CNC's in the beginning, but not anymore "That's what it's about: being curious, and trying, moving towards the kind of work that is your very own---no matter where you learn it." James Krenov :)

bleeth
01-31-2014, 01:15 PM
I love Stickley too but haven't gotten around to fuming white oak yet.

scottp55
01-31-2014, 01:23 PM
I always wondered why Andrew liked that peak in the center of his seat design. Now I know.

Ajcoholic
01-31-2014, 06:14 PM
Scott: Sam Maloof was one of the greats. Do some research and find the spread on his house-It's outrageous. His furniture wax is terrific. They likely still sell it at Rockler. JFK's Rocker was a Maloof. His writings are terrific.
Another great that is worth reading is James Krenov, particularly his Cabinetmakers Notebook.. He has a unique approach to woodworking that I think you would particularly appreciate.

Ive got every book I think Sam wrote... I find his stuff easy to read and very interesting.

I have three of Krenov's books and never finished one yet... his writing is so dry and labouring... I try though.

My father did a lot of stuff similar to Sam Maloof's work - without ever having known who he was. I've always liked the hand carved & shaped styled furniture.. a LOT!

Anyhow, after working like a dog all morning - I had some more spraying/finishing to do this afternoon so between coats I got in another 1 1/2 hours on the rocker...

Rough shaped the front and rear legs, fit the joints and cut the crest rail angles. The next big step is getting the arms roughed out, gluing up the rockers and cutting the 7 back slats. Then the shaping begins...!

But first, I am off to the Turk's and Caicos Islands for a full week - I will be thinking of you guys while Im chiling out by the pool or on the beach with a few "beverages"... heh heh :D

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1612_zps5273da36.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1612_zps5273da36.jpg.html)

Ajcoholic
01-31-2014, 06:15 PM
http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1609_zps5e629d1d.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1609_zps5e629d1d.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1610_zps4db8c99e.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1610_zps4db8c99e.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1602_zps0a05c91f.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1602_zps0a05c91f.jpg.html)

rej
01-31-2014, 06:34 PM
I was there last week and its pretty nice.
have a great time and I love to see your work.

Ajcoholic
01-31-2014, 08:28 PM
I was there last week and its pretty nice.
have a great time and I love to see your work.

We were there the same time (first week of Feb) last year... it was nice for sure. A little warmer than the weather here currently (been in the -30's most of the last month).

khalid
02-01-2014, 07:29 AM
Brilliant work as usual Andrew. I like the style and joinery :) Wish to see the finished master piece.

Ajcoholic
02-15-2014, 06:03 PM
Managed a few more hours on the rocker this past week (even 15 to 20 minutes here and there adds up..)

The rockers I laminate from 8 strips of 1/8" thick - by 1 1/2" wide. I ripped strips from one board on my band resaw, and sanded them on the wide belt. Each rocker will have two accent strips of pau-ferro.

My forms are some dry 2x10 spruce (several years old, so it was dry - and I straightened it out on the jointer, then added another 1/4" of MDF to the face to give me 1 1/2" thick again.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1618_zpsb7677732.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1618_zpsb7677732.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1621_zpsa7c039e8.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1621_zpsa7c039e8.jpg.html)

Ajcoholic
02-15-2014, 06:04 PM
I rough cut the 7 back slats and shaped one - to use as a master to do the 6 remaining ones.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1616_zps740aecf1.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1616_zps740aecf1.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1627_zpsfbb55fb1.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1627_zpsfbb55fb1.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1623_zps395712ab.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1623_zps395712ab.jpg.html)

Ajcoholic
02-15-2014, 06:06 PM
And I rough cut the arms, and started shaping the right side arm. Once I get it to where I like it, I use it to make the left side identical (but a mirror image of course).

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1617_zpsae8e6b52.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1617_zpsae8e6b52.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1631_zpscbc8bed7.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1631_zpscbc8bed7.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1633_zpsfbf838f4.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1633_zpsfbf838f4.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1628_zps1451dbf6.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1628_zps1451dbf6.jpg.html)

Bob Eustace
02-15-2014, 06:30 PM
You know Andrew and Brian should co-author a book so that all this old craftmanship married to CNC doesnt get lost to future woodies.

scottp55
02-15-2014, 06:43 PM
Absolutely gorgeous work Andrew, lam and accents make it your own and stronger, and the back slats look like they'll "give" just that little bit. Question is... Will you ever have time to sit in it?:) Beautiful craftsmanship.

Ajcoholic
02-15-2014, 07:12 PM
I have plans to do more of the work on the SHopbot. But, when I work on a chair like this (one off) and a little bit here and there, it is too easy to fall back on the old way of doing things.

However... I just closed (pretty sure) a job for a huge solid mahogany table, and two show-piece chairs for either end.

I still have some details to hammer out, but I am pretty sure the customer will go with two large solid mahogany chairs in this sort of style (obviously without rockers). That means I will get a chance to have a go at trying to program, and make jigs for holding - for more parts than just the seats.

I would love to do the arms, and the back slats, and the crest rails on the CNC. As soon as I do more than one unit, it makes sense to do it.

I just got about 400 fbm of the nicest 8/4 African mahogany I have ever seen. Arrow straight 12 foot planks, wide and uniform colour and grain. Just gorgeous...

The table I have already priced at $3750. The chairs I am hoping to be able to able to make for the $2000 mark per piece. I know they will go for the table... I will know this week if the chairs will be a go or not... (fingers crossed)

AJC

Ajcoholic
02-15-2014, 07:15 PM
Absolutely gorgeous work Andrew, lam and accents make it your own and stronger, and the back slats look like they'll "give" just that little bit. Question is... Will you ever have time to sit in it?:) Beautiful craftsmanship.

Well to be honest, I dont really even have a place in our home that would comfortably fit a chair of this size... our son's toys have over run our home! But I'll worry about that when I have to.

I just might keep it at work :) Or better yet, someone might want to buy it (as is what happened with the last one I made). However, I would have to sell a rocker like this for about $3800 and not everyone will want to drop that kind of $$ on a chair. But, you never know... I didnt plan to sell the previous one (which I was also making for the home & trade show two years ago).

khalid
02-16-2014, 01:01 AM
Excellent work.

Brian Harnett
02-16-2014, 09:46 AM
Coming along nicely.

scottp55
02-16-2014, 11:54 AM
Andrew, shot this thread to my Dad in an e-mail "The Shopbot is a tool---THIS is Craft". Just got a reply and Dad as a rule doesn't use profanity,
"This person is one h-ll of a good craftsman obviously working in one h-ll of a good shop.

Great to see." :) Thought I'd pass it on.

Ajcoholic
02-16-2014, 08:18 PM
Andrew, shot this thread to my Dad in an e-mail "The Shopbot is a tool---THIS is Craft". Just got a reply and Dad as a rule doesn't use profanity,
"This person is one h-ll of a good craftsman obviously working in one h-ll of a good shop.

Great to see." :) Thought I'd pass it on.

I agree - the shopbot IS a tool... but, so are all my other machines, and also my rasps, chisels and carving tools, various knives, planes, etc.

That's one thing I have a hard time with - when some "traditional" woodworkers suggest using the CNC technology is somehow "cheating". I've hand carved too many furniture parts to know I CAN do it the "old way". I still enjoy doing it - when I can do it on my own time. However, when you are trying to make something in multiples, and for a customer to a particular price point - it makes 100% good sense if you have something to quicken the build time - yet the finish work is still done by "the hands" so to speak.

What I really need to do is probe my arm when I have it finished shaped. I bought the probe when I got my machine 2 years ago - never used it yet. Before I glue on these arms onto the chair I really need to figure out the probe.

Seats I find easy now. Backs are coming along as well.

More complex shapes like the back slats and the arms, I would like to model in Aspire - but I think probing would be a good option.

Tools are tools to me... been there done that :) Want to do it faster, cheaper, and make me more $$ at this point in my life!

Good conversation - I like discussing this stuff. No one around here I know is a real furniture builder but myself. Some cabinet guys (who I enjoy speaking to, dont get me wrong) but I miss spending time with my father, and the guy I used to work with (that now runs my old shop) discussing design, techniques, etc.

ssflyer
02-16-2014, 08:26 PM
Andrew,

I had my probe for quite awhile. before I used it, but when I did, it paid for itself many time over, doing some reproduction lion and gargoyle corbels to match an 18th century wall brought over from Belgium. The probe takes a bit to use properly, and takes a long time to get an accurate, detailed 3D file from, but works well.

ssflyer
02-16-2014, 08:38 PM
BTW, did I mention I'm somewhat in awe of you work? I sometimes myself sitting here, looking at your work and your shop, with my mouth hanging open! :eek:

scottp55
02-16-2014, 08:52 PM
Ron beat me to it Andrew, Always look forward to your posts,but I know my patience level and skills and they don't begin to approach yours. You have a "Knack". This is my limit of patience. Keep up the good work and don't sell this one.:)
p.s., I can finish the small stuff, but notice 15 yrs later the doors are still on the floor on the barrister cases. :)

Ajcoholic
02-16-2014, 09:49 PM
Well, thanks guys. But, I still think of myself as somewhat of an "apprentice". I may have been doing this for a while (gulp.. ill be 44 this year) but there are days when I feel like I'm just fresh out of college, and still hear my father's voice in my head asking what's going on :D

Scott - the best thing I can say is that like most things in life, you either have a passion for it or not. Custom woodworking is what I eat, breathe and dream of 24/7. If you WANT to do something, you just keep at it until you get it. I go to work looking forward to it each day. And in all honesty the biggest disappointment for me is that I know I will probably never come close to making even a small fraction of the things I want to try. I have so many pieces I'd love to try and build (for myself) but of course, when you have a shop to keep running - paid work for customers comes first.

Ideally I would love to prototype new furniture ideas, try new techniques, etc every day.

Ron, I will force myself to get the probe out and use it... :) I know it will pay off. Thanks!

Ajcoholic
02-16-2014, 09:52 PM
p.s., I can finish the small stuff, but notice 15 yrs later the doors are still on the floor on the barrister cases. :)

Man, I thought I was bad for work at home...

I told my wife in 2007 I was doing our kitchen. I am just now actually working on it! I started in August last year, but had to leave it after casing the cabinets. A few weeks ago I said OK that's enough... and have a deadline of the end of March to get it finished. 7 years late, better than never! :)

myxpykalix
02-17-2014, 01:34 AM
Yeah that Honey-do list always seems to come up last:eek:

TimS
02-17-2014, 04:21 AM
Thank you for sharing the photos and progress reports. I've made a half dozen or so Windsor chairs using traditional methods and have pondered tackling some parts of it via CNC (especially the seat as I don't particularly like swinging a gutter adze between my feet).

It's great to see how well it can turn out (Windsor seats are also deeply carved). There was a guy selling CNC-roughed Windsor seats but they were still pretty rough (much larger stepover than you used)….can't find his seats now at the only place I knew that was selling them (Highland Hardware in Atlanta). Yours is much cleaner!

I especially like the attitude that the 'Bot is just a tool. My Windsors were made with hand tools so I heard lots of arguments about which tools were better (hand vs. power)…finally figured out it just doesn't matter, in my shop I get to decide (and experiment/explore/learn).

Looking forward to seeing your finished chair!

Ajcoholic
02-17-2014, 08:04 PM
Worked a little more today (about 45 minutes)...

got the rest of the back slats shaped, the right arm finish rough shaped, and the rockers out of the forms, jointed and planed to finished thickness.

It is starting to look like, gulp, a rocking chair! :D

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1676_zps71b63d5f.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1676_zps71b63d5f.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1649_zps60bfb509.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1649_zps60bfb509.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1660_zps909638b5.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1660_zps909638b5.jpg.html)

scottp55
02-17-2014, 08:11 PM
Love how dense the figuring is on the slats, Same board? What finish are you panning to make it "pop"?

Ajcoholic
02-17-2014, 08:54 PM
Love how dense the figuring is on the slats, Same board? What finish are you panning to make it "pop"?

All the slats are cut from one plank. That was the best one I had.

I will be applying a coat or two of natural Deft Danish oil, then spraying with post-cat lacquer.

The traditional finish for these is an oil and wax finish (typically start with 1/3 raw tung oil, 1/3 boiled linseed and 1/3 satin polyurethane - applied several coats, one per day - then a beeswax and oil finish). However, I prefer the no-maintenence no worry finish that a lacquer provides. The oil brings out the grain (and this red soft maple will turn quite a darker reddish brown) and the lacquer provides a good finish.

If applied well, with minimal coats, and buffed lightly when dry - IMO a lacquer finish is as nice as any oil & wax. And, you don't have to do it once/twice a year for life.

scottp55
02-17-2014, 09:15 PM
Andrew, or anybody, Just getting into lacquers for the the first time, Used Deft Brushing Lacquer just to test on 3 woods,Fumes! Only 12X22' heated shop here and smaller up North at second desktop shop. No room for a booth and NOT opening windows for crossdraft at 0--10F! Anyone had good results with water based Lacquers? 100's of 5X5 and slightly larger, would prefer a "dipping" Lacquer for these items because of ease and quantity. Sorry Andrew started out just to ask you.

Ajcoholic
02-19-2014, 05:58 PM
a little more done after work today...

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1698_zps8b86f217.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1698_zps8b86f217.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1697_zps7c4a98a7.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1697_zps7c4a98a7.jpg.html)

Ajcoholic
02-19-2014, 06:01 PM
Andrew, or anybody, Just getting into lacquers for the the first time, Used Deft Brushing Lacquer just to test on 3 woods,Fumes! Only 12X22' heated shop here and smaller up North at second desktop shop. No room for a booth and NOT opening windows for crossdraft at 0--10F! Anyone had good results with water based Lacquers? 100's of 5X5 and slightly larger, would prefer a "dipping" Lacquer for these items because of ease and quantity. Sorry Andrew started out just to ask you.

I am sorry to say I have zero experience with water based anything. I grew up using solvent based, catalyzed lacquers and solvent based stains. I have brought in some brushing nitrocellulose lacquers for customers (still solvent based) but I havent even used them. I have always worked in a shop (even when I was working for other companies) with proper spray equipment and booths, etc.

scottp55
02-19-2014, 06:13 PM
Thanks Andrew. Looking nice!:) Like how you''ll have your head centered in the grain.

Burkhardt
02-19-2014, 06:30 PM
That looks fabulous. I am envious.

How much (if any) of that work is CNC or is it all hand shaped? Sorry if that was already answered somewhere here.

bleeth
02-19-2014, 07:08 PM
Andrew:
The chair is gorgeous. Well done.
You might start water based by playing with some anoline dyes as a good base on maple. They soak in much better than stain and let you lighten up on the tone.

Ajcoholic
02-19-2014, 08:51 PM
Andrew:
The chair is gorgeous. Well done.
You might start water based by playing with some anoline dyes as a good base on maple. They soak in much better than stain and let you lighten up on the tone.

I use a lot of NGR stains (analine dyes in an alcohol base). I actually have tried a water based analine but the grain raising issue is a PITA.

Ajcoholic
02-19-2014, 08:53 PM
That looks fabulous. I am envious.

How much (if any) of that work is CNC or is it all hand shaped? Sorry if that was already answered somewhere here.

Dont be envious... make one for yourself! :)

On this particular chair, the seat is the only part I did on the CNC, however that saved me several hours of hand carving.

I do want to pursue more CNC carved parts on similar chairs. I am working my way there - as I have done chair legs, backs, etc previously. But when I do multiples.

I know a lot of the rough work can be done on the router... just ned to get time to do the programming or probing.

scottp55
02-20-2014, 05:44 AM
Andrew, on the arm shaping--rasp,drumsander, or one handed routing like Maloof?:)

Ajcoholic
02-20-2014, 09:06 PM
Andrew, on the arm shaping--rasp,drumsander, or one handed routing like Maloof?:)

Mainly do my rough shaping first by free-hand band sawing away some stock, then on the drums of my 108" by 6" edge sander (with a 60 grit or 80 grit belt).

Once the rough shaping of the parts is complete, then the legs/seat/crest rail/arms get attached temporarily with screws, and I use rasps to finish the transitions.

After that, everything gets taken apart - and sanded as best I can before the chair parts get a final assembly with glue. And then the final sanding takes place.

I actually did some more (about 1/2 hour) shaping on one rear leg, and the seat today before I left work. I was in the finishing room most of the day so I didnt have much time.

Tomorrow, I will be spraying again (but finish coats so I will have time between) and some staining to do. I am hoping to get anonther hour at least in on the chair - and you will see it will start to look like a chair VS a bunch of rough cut parts :)

This is where the fun REALLY starts... :D

AJC

scottp55
02-21-2014, 05:40 AM
Yeah, Saw Maloof video of him going at the arms with his bandsaw and was impressed(both by him AND his bandsaw). Trying to figure out how you could improve rear legs? Love how the clean exterior lines "Frame the Flowing". Think that left arm(sitting) will be touched a lot by people seeing it for the first time:)
Now sanding THAT would be a pleasure!

Ajcoholic
02-21-2014, 08:11 PM
You have to be very careful and know what to expect when using the band saw in this manner. It is very easy for the blade to grab and twist the piece out of your hand, jam up or break the blade.

Ive been using the band saw since I was 10 yrs old. My father made a plywood box so I could reach up to the table on the old Rockwell/Delta 14" saw we had in our old shop. I thought I had arrived when I was allowed to start cutting things on that saw... :) 34 yrs later... I still watch myself each and every time.

Today I was doing some finishing work - spraying some cabinets, and also staining a bedroom set. In between coats I got in about 2 hours on the chair. I screwed the arms/legs/seat together, and finished rough shaping the parts.

The back legs, crest rail, seat are all ready now for the sanding to begin. Blending the rough shaping... starting with 80 grit in the ROS and rasps...

AFter the rough sanding in done then I can glue everything together and start the fine stuff. But now it REALLY looks like a piece of furniture. Also, I got to sit in it for the first time... I forgot how nice these feel... just fit your body like a glove.

AJC

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1730_zps7b16c9c1.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1730_zps7b16c9c1.jpg.html)

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Ajcoholic
03-06-2014, 07:42 PM
So yesterday and today I got back to the rocker. Sanded/shaped the joints, and glued up the rocker. Everything is sanded to 120 grit at this stage. Once the crest rail is faired in, I can sand the whole chair finer by hand.

I used West systems epoxy to glue the chair together, woith a little wood dust to thicken it up and fill any small gaps in the joints. I brush on a coat to both surfaces first (un thickened) to allow it to penetrate. Then brush on a coat of the thickened epoxy. Put the joint together, and wipe off the excess. Makes a super strong joint that will never come apart.

The rockers are the last major part to take care of. I have exactly 20 hurs in the chair to date. I am aiming for 25 hrs pre-finishing. That is a lot of time savings from my last one.. I have to thank the CNC, and also the Festool rotex 125 and 90 sanders. They make the shaping a LOT faster for me.

AJC

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1788_zps2c121b45.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1788_zps2c121b45.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1796_zpsa90482ed.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1796_zpsa90482ed.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1798_zpseb7f004d.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1798_zpseb7f004d.jpg.html)

scottp55
03-07-2014, 07:24 AM
Andrew, How far does the West penetrate the maple? Looks like it cleaned up well, just interested in how much you had to take off. Is there much difference on end grain penetration? Only ever done polyester resin on end-grain Balsa construction with fiberglass.

Brian Harnett
03-07-2014, 07:27 AM
Chair is coming along great, I cant get over how clean your shop is.

Mine looked like that once before I started doing anything in it.

bobmoore
03-07-2014, 08:12 AM
Beautiful work as ussual Andrew. Nice brief description of the proper way to apply West Epoxy. As you stated, use wood flour from a sander not saw dust. The thicker you make the second coat the easier it is to shape after it cures.
Bob

khalid
03-07-2014, 10:14 AM
Andrew.. The chair coming out very elegant and beautiful. I just saw the glass window in your posted picture and found pine trees, i imagine a beautiful landscape out there. You are lucky man.

Ajcoholic
03-07-2014, 06:33 PM
Thanks! Yes, the scenery out the windows is pretty here. Especially if you like spruce and pine trees :)

I got the rockers shaped and glued on! The end is near....

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1816_zps1890af90.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1816_zps1890af90.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1815_zpsa29597bd.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1815_zpsa29597bd.jpg.html)

scottp55
03-07-2014, 06:42 PM
Wow Andrew, I hadn't thought the lam accent through! Very fluid. Like your little "kick" at the end. I think it will like to rock:) Beautiful!

Ajcoholic
03-10-2014, 07:52 PM
Well, the rocker has been shaped, finish sanded and oiled. Spent another two 1/2 hours on it this morning. Decided to get it out of the way as the rest of the week is going to be spraying, sanding and running millwork (busy, busy!)

Hope you like it.. really enjoyed building it and man it is kind of a let down to be finished. I really enjoy the process of the build the most.

Now onto the mahogany dining chairs!

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1832_zps2ec95dc7.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1832_zps2ec95dc7.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1831_zps2b916664.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1831_zps2b916664.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1825_zps1f75aedf.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1825_zps1f75aedf.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1826_zps45fd37ca.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1826_zps45fd37ca.jpg.html)

Ajcoholic
03-10-2014, 07:53 PM
http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1825_zps1f75aedf.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1825_zps1f75aedf.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1828_zps999b088f.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1828_zps999b088f.jpg.html)

scottp55
03-10-2014, 09:06 PM
Andrew, That has to be the prettiest piece of lumbar support I've EVER seen :)
Job exceptionally well done! Tain't half bad :)

myxpykalix
03-10-2014, 09:21 PM
Man that is a work of art:eek: Let me ask a dumb question...why are the rockers extra long? I don't know why you don't consider putting together some type of weekend or week long class to teach some of this...
I hope you wear "yours" with pride:D

gundog
03-11-2014, 01:12 AM
Very nice work as usual.

Ajcoholic
03-11-2014, 09:03 PM
Man that is a work of art:eek: Let me ask a dumb question...why are the rockers extra long? I don't know why you don't consider putting together some type of weekend or week long class to teach some of this...
I hope you wear "yours" with pride:D

So when you get a little crazy, you won't flip over backwards! :D

It's just the design of the rocker. They look great in person, not abnormally long.

As for teaching, that's not my real strong trait. Plus I am too busy working

And yes I wear my hat every day, and my work shirts too proudly :)

Ajcoholic
03-21-2014, 09:13 PM
well, after a week of letting the danish oil dry, I put three coats of lacquer on the rocker. only thing left it to let it dry and next week I will rub it out with 4 ought steel wool and some wax.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1866_zps7466ea0b.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1866_zps7466ea0b.jpg.html)

scottp55
03-22-2014, 03:39 AM
Andrew,Watco clear? What wood are the plugs? Same as lam accent? REALLY came out nice! Should give long-tailed animals an anxiety attack:)

Ajcoholic
03-23-2014, 02:03 PM
Andrew,Watco clear? What wood are the plugs? Same as lam accent? REALLY came out nice! Should give long-tailed animals an anxiety attack:)

Well, we used to use Watco for years. It is a linseed oil based Danish oil mix. The past several years, I switched to Deft - it is easier to get up here. Deft Danish oil is a heavier oil, and dries much quicker I find, and also has a greater build. It is a tung oil based Danish oil. They are both an oil/varnish mix but I think I prefer Deft. They come in the same colours and I use the natural (clear - but with a light amber tint) a lot just to enhance the grain in woods like Walnut, Cherry, Mahogany, etc. I rarely bother with maple, oak, ash, etc. A coat of clear oil really brings out the character in the wood, vs just applying a top coat finish as the lacquer really doesnt soak into the wood - it sits on the surface and doesnt bring out all the subtleties in the wood grain.

Ajcoholic
03-23-2014, 02:06 PM
Oh yeah - the rocker's plugs, and strips for contrast in the rockers is Pau Ferro. A wood very similar to some rosewoods - oily and dense, and smells like roses when you cut and sand it. It ranges from reddish brown to quite dark brown.

I'd love to make a solid Pau Ferro chair one day. But the wood is in the mid $20's per BF for 4/4, and I am not sure 8/4 is even available now.

When I was a kid, my dad loved Pau Ferro and had a whole pile of it in the shop. He made my mom an entire dining room set (table and 8 chairs) from it. Today, that would cost you several thousands just for the wood.

AJC

Ajcoholic
03-24-2014, 06:59 PM
So its done completely.

Rubbed out the lacquer with 0000 steel wool this morning.

Tried to take a few outside photos in natural light...

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1150_zpsdce674f0.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1150_zpsdce674f0.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_1153_zps965316f1.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_1153_zps965316f1.jpg.html)

scottp55
03-24-2014, 07:11 PM
Needs to be rubbed out more with body temperature cloth. Preferably your most comfortable:) Is it as comfortable as it looks? Does it "Like" to rock? Most important question--Will you ever sit still long enough to enjoy it:)

Ajcoholic
03-24-2014, 10:01 PM
Needs to be rubbed out more with body temperature cloth. Preferably your most comfortable:) Is it as comfortable as it looks? Does it "Like" to rock? Most important question--Will you ever sit still long enough to enjoy it:)

Yes it is very comfortable...
Yes it likes to rock...
Possibly in about 22 to 25 more years... :D

myxpykalix
03-25-2014, 02:45 AM
AJ,
I believe my mother was rocked in this chair, i was rocked in this chair, i rocked my children in this chair, they have rocked their children in this chair, and someday (not soon i hope) they will rock their children in this chair.

Your chair will be around for generations and your childrens childrens children will be rocking their children in it long after you are dust. You really should mark it with a branding iron or some permanant marking for future generations to know where it came from because it clearly is a heirloom piece.
I predict it will be on "Antiques Roadshow 2125"

rej
03-25-2014, 08:32 AM
I agree.
it is a work of art. thank you for posting all of this.