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Discussion Starter · #1 ·
First progress report

Okay I started this chair Jan 28th 2010 I wanted to get finish put on after 30 days…... simple goal eh?

To my credit I got everything I could have done until I needed to use th 1/2'' rabbit and 3/4 round over I did not have but ordered took 10 days to get here )-:

So far total working days possible - 16

Progress



This is a rocker design by Hal Taylor, I purchased his templates, PDF book, and video. I was at first a little on the fence as it started to add up already with just the costs for Hal's stuff. I must say it was worth it, everything you get helps you tremendously!

I'm using wormy soft maple that was cut about 5 yrs ago by my brother on his woodmizer air dried, 3'' thick!

So I easily dressed it to the required dimensions, and was happy that all the gray stain planed away taking it from 3'' to just over 2'', now I kinda wish I had my MM20 setup at the point to resaw some wood, at least for drawers or something.

Anyways I meant to have a daily update I did not and still won't but I will update frequently as I work on it and I will be working over time…lol

I have taken pictures of all parts so far



I have almost finished the seat including leg joints






Arms have been coved on the table saw and cut to shape



Legs have had a lot of work on them!

Head rest is cut out ready to be mounted ( dang forgot to take that picture BRB )

...

...
...

....
Okay took the picture


Back braces have been all glued up



Rockes have been glued up and cleaned up 80%




Front legs have also had lot's of work done to them



I guess that's all the parts, not to many but lot's of time!

Oh here's a pic of tools used on seat to make it purdy, and in my opinion the best tool of course in the angle grinder with kutzall disc. BUT in a close second I must say the hand scraper is an amazing tool, I only started using one a couple months ago, keep her sharp and it's a dream to use….. I do burn my fingers though. (-:

 

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First progress report

Okay I started this chair Jan 28th 2010 I wanted to get finish put on after 30 days…... simple goal eh?

To my credit I got everything I could have done until I needed to use th 1/2'' rabbit and 3/4 round over I did not have but ordered took 10 days to get here )-:

So far total working days possible - 16

Progress



This is a rocker design by Hal Taylor, I purchased his templates, PDF book, and video. I was at first a little on the fence as it started to add up already with just the costs for Hal's stuff. I must say it was worth it, everything you get helps you tremendously!

I'm using wormy soft maple that was cut about 5 yrs ago by my brother on his woodmizer air dried, 3'' thick!

So I easily dressed it to the required dimensions, and was happy that all the gray stain planed away taking it from 3'' to just over 2'', now I kinda wish I had my MM20 setup at the point to resaw some wood, at least for drawers or something.

Anyways I meant to have a daily update I did not and still won't but I will update frequently as I work on it and I will be working over time…lol

I have taken pictures of all parts so far



I have almost finished the seat including leg joints






Arms have been coved on the table saw and cut to shape



Legs have had a lot of work on them!

Head rest is cut out ready to be mounted ( dang forgot to take that picture BRB )

...

...
...

....
Okay took the picture


Back braces have been all glued up



Rockes have been glued up and cleaned up 80%




Front legs have also had lot's of work done to them



I guess that's all the parts, not to many but lot's of time!

Oh here's a pic of tools used on seat to make it purdy, and in my opinion the best tool of course in the angle grinder with kutzall disc. BUT in a close second I must say the hand scraper is an amazing tool, I only started using one a couple months ago, keep her sharp and it's a dream to use….. I do burn my fingers though. (-:

Good progress
 

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Discussion Starter · #3 ·
First progress report

Okay I started this chair Jan 28th 2010 I wanted to get finish put on after 30 days…... simple goal eh?

To my credit I got everything I could have done until I needed to use th 1/2'' rabbit and 3/4 round over I did not have but ordered took 10 days to get here )-:

So far total working days possible - 16

Progress



This is a rocker design by Hal Taylor, I purchased his templates, PDF book, and video. I was at first a little on the fence as it started to add up already with just the costs for Hal's stuff. I must say it was worth it, everything you get helps you tremendously!

I'm using wormy soft maple that was cut about 5 yrs ago by my brother on his woodmizer air dried, 3'' thick!

So I easily dressed it to the required dimensions, and was happy that all the gray stain planed away taking it from 3'' to just over 2'', now I kinda wish I had my MM20 setup at the point to resaw some wood, at least for drawers or something.

Anyways I meant to have a daily update I did not and still won't but I will update frequently as I work on it and I will be working over time…lol

I have taken pictures of all parts so far



I have almost finished the seat including leg joints






Arms have been coved on the table saw and cut to shape



Legs have had a lot of work on them!

Head rest is cut out ready to be mounted ( dang forgot to take that picture BRB )

...

...
...

....
Okay took the picture


Back braces have been all glued up



Rockes have been glued up and cleaned up 80%




Front legs have also had lot's of work done to them



I guess that's all the parts, not to many but lot's of time!

Oh here's a pic of tools used on seat to make it purdy, and in my opinion the best tool of course in the angle grinder with kutzall disc. BUT in a close second I must say the hand scraper is an amazing tool, I only started using one a couple months ago, keep her sharp and it's a dream to use….. I do burn my fingers though. (-:

How do you reply so fast so many times? lol

and thank you
 

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First progress report

Okay I started this chair Jan 28th 2010 I wanted to get finish put on after 30 days…... simple goal eh?

To my credit I got everything I could have done until I needed to use th 1/2'' rabbit and 3/4 round over I did not have but ordered took 10 days to get here )-:

So far total working days possible - 16

Progress



This is a rocker design by Hal Taylor, I purchased his templates, PDF book, and video. I was at first a little on the fence as it started to add up already with just the costs for Hal's stuff. I must say it was worth it, everything you get helps you tremendously!

I'm using wormy soft maple that was cut about 5 yrs ago by my brother on his woodmizer air dried, 3'' thick!

So I easily dressed it to the required dimensions, and was happy that all the gray stain planed away taking it from 3'' to just over 2'', now I kinda wish I had my MM20 setup at the point to resaw some wood, at least for drawers or something.

Anyways I meant to have a daily update I did not and still won't but I will update frequently as I work on it and I will be working over time…lol

I have taken pictures of all parts so far



I have almost finished the seat including leg joints






Arms have been coved on the table saw and cut to shape



Legs have had a lot of work on them!

Head rest is cut out ready to be mounted ( dang forgot to take that picture BRB )

...

...
...

....
Okay took the picture


Back braces have been all glued up



Rockes have been glued up and cleaned up 80%




Front legs have also had lot's of work done to them



I guess that's all the parts, not to many but lot's of time!

Oh here's a pic of tools used on seat to make it purdy, and in my opinion the best tool of course in the angle grinder with kutzall disc. BUT in a close second I must say the hand scraper is an amazing tool, I only started using one a couple months ago, keep her sharp and it's a dream to use….. I do burn my fingers though. (-:

Very cool project and a great blog. I really respect you guys that make these chairs. They're unbelievably beautiful. The backstory on the wood is cool too. Was the time constraint self-imposed? If so why? That seems pretty ambitious to me, but what do I know. My non-woodworking friends would point out that at that rate you could make 12 chairs a year and sell them for mucho dinero.
 

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Discussion Starter · #5 ·
First progress report

Okay I started this chair Jan 28th 2010 I wanted to get finish put on after 30 days…... simple goal eh?

To my credit I got everything I could have done until I needed to use th 1/2'' rabbit and 3/4 round over I did not have but ordered took 10 days to get here )-:

So far total working days possible - 16

Progress



This is a rocker design by Hal Taylor, I purchased his templates, PDF book, and video. I was at first a little on the fence as it started to add up already with just the costs for Hal's stuff. I must say it was worth it, everything you get helps you tremendously!

I'm using wormy soft maple that was cut about 5 yrs ago by my brother on his woodmizer air dried, 3'' thick!

So I easily dressed it to the required dimensions, and was happy that all the gray stain planed away taking it from 3'' to just over 2'', now I kinda wish I had my MM20 setup at the point to resaw some wood, at least for drawers or something.

Anyways I meant to have a daily update I did not and still won't but I will update frequently as I work on it and I will be working over time…lol

I have taken pictures of all parts so far



I have almost finished the seat including leg joints






Arms have been coved on the table saw and cut to shape



Legs have had a lot of work on them!

Head rest is cut out ready to be mounted ( dang forgot to take that picture BRB )

...

...
...

....
Okay took the picture


Back braces have been all glued up



Rockes have been glued up and cleaned up 80%




Front legs have also had lot's of work done to them



I guess that's all the parts, not to many but lot's of time!

Oh here's a pic of tools used on seat to make it purdy, and in my opinion the best tool of course in the angle grinder with kutzall disc. BUT in a close second I must say the hand scraper is an amazing tool, I only started using one a couple months ago, keep her sharp and it's a dream to use….. I do burn my fingers though. (-:

Ya I imposed the time frame on my self it may seem like not very long but I think If I stay the course, i'll be on my second chair in no time!

The wood is turning out to be very beautiful, at first I used it just to not waste walnut, but now i'm very glad I choose this wood, these style of chairs really show off woods beauty, so anyone wanting to make a " maloof " inspired rocker should use beautiful wood from chair #1. The worm holes and staining will really pop come finish time (-:
 

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Discussion Starter · #6 ·
back leg shaping

Today I did some shaping on the rear joints using the kerf marks I made at the top and bottom of the seat I cut then sanded a nice profile. Also cut some angles to allow the head rest to flow into the legs. You can't tell but I worked for a few hours on them legs.









 

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back leg shaping

Today I did some shaping on the rear joints using the kerf marks I made at the top and bottom of the seat I cut then sanded a nice profile. Also cut some angles to allow the head rest to flow into the legs. You can't tell but I worked for a few hours on them legs.









Looking good.
Edit to add: I see you are using Hal's video et al…I ordered mine Sunday. Hard maple is what I plan on using but only because it is what I have. I will be following your blog with heightened interest.
 

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back leg shaping

Today I did some shaping on the rear joints using the kerf marks I made at the top and bottom of the seat I cut then sanded a nice profile. Also cut some angles to allow the head rest to flow into the legs. You can't tell but I worked for a few hours on them legs.









Love the wormy! Your skill at shaping things up is top shelf Bandsaw class 505 Professional course. This is going to be beautiful when complete.
 

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back leg shaping

Today I did some shaping on the rear joints using the kerf marks I made at the top and bottom of the seat I cut then sanded a nice profile. Also cut some angles to allow the head rest to flow into the legs. You can't tell but I worked for a few hours on them legs.









I know this is a super old blog, but reading through everything inspired me. I just ordered the materials from Hal as well..reading the ebook as I look at your blog for the hundreth time. Can't wait for the template stuff to show up!
 

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Discussion Starter · #10 ·
back leg shaping

Today I did some shaping on the rear joints using the kerf marks I made at the top and bottom of the seat I cut then sanded a nice profile. Also cut some angles to allow the head rest to flow into the legs. You can't tell but I worked for a few hours on them legs.









camps764 - Thanks for the message, glad I got you inspired to build your self a chair, but I warn you now you'r traveling down a dark path in which you might build more then one!

Hal Taylors instruction is top notch and his chair is so comfortable it will know your socks off. I'm excited for you!
 

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Discussion Starter · #11 ·
Shaped front legs, attaching back legs

I have been doing some work over the past few days since my last up date. In this series it just shows me doing the glue up on the rear legs, and shows off the now shaped front legs.

I made some 6 degree wedges for the sides and some square blocks for the rear as per Hals instructions, he even has a special way of making the blocks.

It's funny cause I've read his book so much, and watched the video over and over it feels like I know the guy but really I've never even spoken to him, other then e-mail and that was because I was going to back out of getting the plans…..doh!

So ya feel like I know him but never met him.







 

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Shaped front legs, attaching back legs

I have been doing some work over the past few days since my last up date. In this series it just shows me doing the glue up on the rear legs, and shows off the now shaped front legs.

I made some 6 degree wedges for the sides and some square blocks for the rear as per Hals instructions, he even has a special way of making the blocks.

It's funny cause I've read his book so much, and watched the video over and over it feels like I know the guy but really I've never even spoken to him, other then e-mail and that was because I was going to back out of getting the plans…..doh!

So ya feel like I know him but never met him.







Looks like it's gonna be very nice looking rocker. Can't wait to see it in complete form.
 

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Shaped front legs, attaching back legs

I have been doing some work over the past few days since my last up date. In this series it just shows me doing the glue up on the rear legs, and shows off the now shaped front legs.

I made some 6 degree wedges for the sides and some square blocks for the rear as per Hals instructions, he even has a special way of making the blocks.

It's funny cause I've read his book so much, and watched the video over and over it feels like I know the guy but really I've never even spoken to him, other then e-mail and that was because I was going to back out of getting the plans…..doh!

So ya feel like I know him but never met him.







Hi Paul;

Looks like quite a project.

Lee
 

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Discussion Starter · #14 ·
Fitted head rest, cleaned up seat joints

So ya I made the head rest a while ago, and now i'm finally attaching it, holes are drilled mouth head rest kerf the top, draw radius, cut radius ( top and bottom ), shape bottom, attach in place add large round over to top.

I've cleaned up the joints to near perfection! (-: at least by my standards maybe not Hals but i'll do even better on my next chair which will be out of walnut I think maybe cherry but i'd rather do one out of walnut.

The way the legs are built most of the shaping is done before the legs are even attached to the chair, after glue up there's work left yes…... but not too much.

I used a drum sander on my drill and palm sander to get a nice fair curve everywhere.











 

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14,504 Posts
Fitted head rest, cleaned up seat joints

So ya I made the head rest a while ago, and now i'm finally attaching it, holes are drilled mouth head rest kerf the top, draw radius, cut radius ( top and bottom ), shape bottom, attach in place add large round over to top.

I've cleaned up the joints to near perfection! (-: at least by my standards maybe not Hals but i'll do even better on my next chair which will be out of walnut I think maybe cherry but i'd rather do one out of walnut.

The way the legs are built most of the shaping is done before the legs are even attached to the chair, after glue up there's work left yes…... but not too much.

I used a drum sander on my drill and palm sander to get a nice fair curve everywhere.











Oooooh, smooth & fluent curves and contours!
 

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Fitted head rest, cleaned up seat joints

So ya I made the head rest a while ago, and now i'm finally attaching it, holes are drilled mouth head rest kerf the top, draw radius, cut radius ( top and bottom ), shape bottom, attach in place add large round over to top.

I've cleaned up the joints to near perfection! (-: at least by my standards maybe not Hals but i'll do even better on my next chair which will be out of walnut I think maybe cherry but i'd rather do one out of walnut.

The way the legs are built most of the shaping is done before the legs are even attached to the chair, after glue up there's work left yes…... but not too much.

I used a drum sander on my drill and palm sander to get a nice fair curve everywhere.











Very nice work Paul !
Acton Ontario is my hometown :)
 

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Fitted head rest, cleaned up seat joints

So ya I made the head rest a while ago, and now i'm finally attaching it, holes are drilled mouth head rest kerf the top, draw radius, cut radius ( top and bottom ), shape bottom, attach in place add large round over to top.

I've cleaned up the joints to near perfection! (-: at least by my standards maybe not Hals but i'll do even better on my next chair which will be out of walnut I think maybe cherry but i'd rather do one out of walnut.

The way the legs are built most of the shaping is done before the legs are even attached to the chair, after glue up there's work left yes…... but not too much.

I used a drum sander on my drill and palm sander to get a nice fair curve everywhere.











Excellent joint work!
 

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Discussion Starter · #18 ·
Fitted head rest, cleaned up seat joints

So ya I made the head rest a while ago, and now i'm finally attaching it, holes are drilled mouth head rest kerf the top, draw radius, cut radius ( top and bottom ), shape bottom, attach in place add large round over to top.

I've cleaned up the joints to near perfection! (-: at least by my standards maybe not Hals but i'll do even better on my next chair which will be out of walnut I think maybe cherry but i'd rather do one out of walnut.

The way the legs are built most of the shaping is done before the legs are even attached to the chair, after glue up there's work left yes…... but not too much.

I used a drum sander on my drill and palm sander to get a nice fair curve everywhere.











It's worth the drive eh john?
 

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2,418 Posts
Fitted head rest, cleaned up seat joints

So ya I made the head rest a while ago, and now i'm finally attaching it, holes are drilled mouth head rest kerf the top, draw radius, cut radius ( top and bottom ), shape bottom, attach in place add large round over to top.

I've cleaned up the joints to near perfection! (-: at least by my standards maybe not Hals but i'll do even better on my next chair which will be out of walnut I think maybe cherry but i'd rather do one out of walnut.

The way the legs are built most of the shaping is done before the legs are even attached to the chair, after glue up there's work left yes…... but not too much.

I used a drum sander on my drill and palm sander to get a nice fair curve everywhere.











That,s funny !! I was actually going to say that myself :) I lived there for roughly 10 years as a kid . My father stayed much longer .
 

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Discussion Starter · #20 ·
Attaching arms

Stayed up way late last night to get these arms attached I wanted the glue to cure over night.

I followed the instructions from Hal about how to " fix " the joint, I actually used a 80grit 9'' stick on sanding disk and a piece of 120 from my drum sander, both worked great because they are stiff paper.

Basically attach the arm where it should be, put sand paper between joint and pull, sounds easy looks easy but it did take me a few minutes to get the hang of it, mine needed more of a wiggle pull to get the job done but once your close it's work like magic and the joint make a seam you can hardly see.

I " primed " the end grain with titebond 3, applied my glue to the other surfaces and away I went, I used the blocks that were cut while band sawing the added piece and a caul on top.

Yes Hal if you see this post I used a F clamp or two maybe not up to your standards…..lol but it looks like a great joint so far.







 
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