Thread: Rocker WIP

No I would certainly not be making this for profit. I would never infringe on someone elses design in that way. I am just a back yard hack having a go. I don't sell anything that I make.

Right, the back is starting to take shape. Cut this out of a solid piece as I've never done bending before and thought I'd save it for another day. Morticed it into the bottom rail. Yet to do the top tenon, should be interesting as it needs to fit into the curved head rest.

Sorry for the delay but I have been flat out bulding a house. Spent the day scooping my first seat and It was certainly an experience.

I decided to use a method I found on youtube which involves cutting with the table saw and then finishing by hand.

1. Boards glued up and marked ready. A piece of 6mm ply glued across the front edge so that when I cut with the table saw, the seat slopes down slightly.

2. I used the table saw to remove the straight cuts. I did this on the sled.

3. Shallower cuts to meet the curve of the seat.

4. I used the belt sander with an 80 grit belt to carve out the basic shape. I found the left hand side (as you look at it in the photo) fairly easy to shape, but had a much tougher time with the right hand side due to my right handedness. Ended up with a few divots and not quite as even.

5. I carved further with a 60 grit flapper disc (back of photo) in a five inch grinder. These are only about $8 from Bunnies as opposed to a fair bit more for those carving discs. I found this to be a really good way to remove bulk material quickly. Had to be very careful though as it could cut in quite easily. If you try this technique, I'd suggest a very light touch and maybe a bit of practice on some scrap to get a feel. 60 grit may have been a bit harsh as well.

6. Enough for today. The saet still requires a lot of hand sanding, as well as shaping.

Impressive work so far, can't wait to see the finished chair.

SB

I think you are doing very well. Maybe next time you could do the seat just by hand tools.

Guess it's hard to see the $7500 at first.....but when you've gotten to where you are now, perhaps one wonders. There is certainly a lot of work and thought in the project, and it is indeed an artful piece.

Obviously the original designer must have given sufficient thought to the weight distribution and points of bearing, otherwise it would be wide open for the legal eagles if the structure failed (which I'm sure it won't).

You have made a faithful representation of the original; that in itself would be a credit to you.. the finished product? By the looks so far, as good as it can get.

Originally Posted by Christos

Maybe next time you could do the seat just by hand tools.

I would have liked to but didn't have the required hand tools for the job, all my planes have flat soles as I haven't done much curved work to date. Something for the future...
It was hard enough going with the power tools. I do use hand tools a lot in most projects.

Originally Posted by wun4us

Guess it's hard to see the $7500 at first.....but when you've gotten to where you are now, perhaps one wonders. There is certainly a lot of work and thought in the project, and it is indeed an artful piece.

Obviously the original designer must have given sufficient thought to the weight distribution and points of bearing, otherwise it would be wide open for the legal eagles if the structure failed (which I'm sure it won't).

You have made a faithful representation of the original; that in itself would be a credit to you.. the finished product? By the looks so far, as good as it can get.

Thanks for the vote of confidence, there are plenty of mistakes in mine though. I don't think I have the weight distribution perfect, the back being too upright, but I always knew that this one would be a "trial run". As for the $7500, I guess it keeps them exclusive...

Originally Posted by yowie

As for the $7500, I guess it keeps them exclusive...

As they most certainly are

Originally Posted by wun4us

As they most certainly are

Well, I'll have one!

A bit more work on the seat today. getting fairly close to the finished product I think, probably roll the front as well though.

Well the weather in Perth has been a bit crap for diving this week so managed to spend a bit of time in the shed. Starting to get close to the finished product now, still have the arms to do and a lot of finishing. Also going to lower the headrest about 75mm as it is a bit high and I am also not happy with the mortice into the bottom of the headrest. It was a tough one to get right as it is curved as well as angled from front to back, plus having to be lined up perfectly with the mortices of the sides into the headrest which are also curved and angled front to back. AARGH!!

1. The cross brace that the front of the seat will be attached to, morticed into the sides. Also the piece on the backsplat that will support the back of the seat. The back of this had to be curved to fit the profile of the back splat. I don't know why I chose this design, it was a PITA to get right.

2. Cutting the mortices for the seat supports to fit into.

3. And then it broke.

4. The new, much simpler design and the seat supports.

5. The mortices in the front cross member

6. Dry fitted

7. Seat glued to the front member. The seat and front cross member will be shaped together once dry.

8. The headrest, which I intend to lower by 75mm, roughly to the bottom of the white tape.

Oh yeah, I was thinking of finishing it with that minmax poly wipe on stuff. Do you think this would be alright for this purpose?