Making Rocker's Rocker

**DPB** · 21st April 2005, 10:19 PM

Although the progress isn't that obvious, the picture below records what has been done since the last post.

I've glued the rocker blocks to the rockers, routed dowel holes in the bottom and top of the front legs, and the top of the front rocker blocks. I cut the back legs to the required length. Tomorrow I will route holes in the bottom of the back legs, rear rocker blocks and in the arms of the rocker and the back legs where the arms attach.

The picture shows the rocker dry-fit assembled (except for the arms) with five of the six back-slat laminations in place but not cut to length or inserted into the mortises. It provides a fairly good view of how it will look.

I had help from Peter Jurrjens cutting the back legs because I don't have a CMS. Unfortunately, Rocker's instructions assume that all CMS have a head that tilts both sides of vertical to achieve the necessary compound angle of cut on both legs. Peter's saw only tilts one way. So I ended up cutting the angle with a hand saw and had a little difficulty determining the necessary angle. It really doesn't become apparent until it is assembled as seen in this picture. It is true that Rocker's instructions urge a conservative and cautious approach in determining this angle, but never-the-less, it is difficult to determine the correct angle of cut.

I used to think that building a wooden boat would be difficult, but as there are virtually no right angles on the rocker, determining the correct angle of some cuts is a real challenge.

**DPB** · 29th April 2005, 04:02 PM

Mmm... no replies since last post over a week ago. Do I keep going, or is this just too boring?

This is what have I done since my last post.

- Fitted the joints where the legs meet the rockers. As explained in my last post this was done with hand tools. I discovered you don't get too many attempts to get this right. You hand plane and chisel the faces of the joint to get a close fit. But if you get it wrong, you run out of wriggle room and nothing else will fit. I think my fits are OK - not perfect, but very close.
- Finished all of the formed back slats and fitted two on the bottom rail.
- Routed all of the dowel joint holes (16 holes, 8 joints in total).
- Fitted the joint where the arms meet the back legs with hand tools.
- Cut arms to shape on bandsaw and faired.
- Glued the dowels into the bottom of the legs, back of the arms and top of the front legs.
- Faired two of the leg blocks (right side when seated) to blend into the bottom of the legs.
- Faired the back of the arms to blend into the back legs.

The pictures below show the components dry fitted. Some of the joints don't look quite flush, but remember, there is no clamping pressure on them to bring them togeter.

What's next? A lot of fairing and sanding. Also need to finish fitting the back-slats into the bottom rail and carefully cut to length to fit into the mortises in the top rail. First glue-up is probably still two weeks away depending on how much time I get to work on this project. And I haven't even started on the seat frame.

If you want me to clarify any of this, please let me know.

**silentC** · 29th April 2005, 04:27 PM

Keep going, by all means. I've been keeping up with the progress and I'm sure it will be a valuable reference for anyone who wants to build one.

**Gumby** · 29th April 2005, 04:29 PM

You know some of us are just lurking...........I'm not commenting because it's way past my standard and I don't wish to look like an idiot. (I know, I already do!

)

**bitingmidge** · 29th April 2005, 04:38 PM

What Gumby says!

P

**ryanarcher** · 29th April 2005, 05:31 PM

Looks like you're doing a wonderfull job Don! Please PLEASE keep going with the posts. we just found out that SWMBO's knocked up again and the rocker has been moved to #1 on the honey-do list by executive decision. I'll be doing well if i can equal your performance.

-ryan

**Wongo** · 29th April 2005, 05:35 PM

Don, I cannot wait to see the final product.

**Rocker** · 29th April 2005, 05:48 PM

Don,

It looks as though you are well over the hump now. There is just a good deal of rather tedious rounding over, rasping, chiselling and sanding. If you are using a router for rounding over, be careful not to risk disastrous tear-out by routing against the grain; you need to climb-cut in places, but I didn't attempt rounding over the sharp curves near the joints with a router. The seat frame is very easily made with the morticing jig, but fitting the rear glue blocks can be a bit tricky, especially if you don't have a SCMS that can cut the required 40° angles.

You have not explained how you routed the dowel holes for the dowel joints joining the legs to the rockers, and the arms to the legs. For those who don't have my rocker CD, I will explain the cunning jig I designed to ensure that the dowel holes are perpendicular to the plane of the joint that they are joining. Regular dowelling jigs will not work, because the plane of the joints in the chair are not normally perpendicular to adjacent faces.

The jig is shown below; it is just a piece of 12 mm MDF with a 5/8" hole drilled in its centre with a forstner bit. There are two small screw holes, enabling the jig to be centred on the position of the dowel hole and screwed in place. The dowel hole is then routed with a router fitted with a 1/2" spiral bit and a 5/8" OD template guide which is fitted into the hole in the jig.

Rocker

**Sturdee** · 29th April 2005, 05:53 PM

Originally Posted by DPB

Mmm... no replies since last post over a week ago. Do I keep going, or is this just too boring?

Keep going Don, love to read the progress.

Been too dumbfounded to comment after seeing the instruction you have to follow. Keep it up.

Peter.

**DPB** · 29th April 2005, 05:54 PM

Originally Posted by ryanarcher

Looks like you're doing a wonderfull job Don! Please PLEASE keep going with the posts. we just found out that SWMBO's knocked up again and the rocker has been moved to #1 on the honey-do list by executive decision. I'll be doing well if i can equal your performance.

-ryan

Congratulations, Ryan! And regards to your lady.

Aidan will have to move over and share your love with a sibling.

Actually, that isn't the case. I discovered after having our second child, that in spite of believing I couldn't love another child as much as my first, my second child didn't have to share my love with her sister, and that my capacity to love my second daughter expanded my ability to love without detracting from the love of my first child.

**Rocker** · 29th April 2005, 05:57 PM

Ryan,

Congratulations. I think you should still have plenty of time to build a rocker or three before the happy event

Rocker

**Gumby** · 29th April 2005, 07:25 PM

Originally Posted by DPB

I discovered after having our second child, that in spite of believing I couldn't love another child as much as my first, my second child didn't have to share my love with her sister, and that my capacity to love my second daughter expanded my ability to love without detracting from the love of my first child.

That's exactly the same for me. I thought after my son was born that I couldn't feel that again but when his brother came along 14 months later, you just create more feeling. Simple.

Actually it's my eldest's 21st tomorrow night so I'm a bit emotional about it all. I've just finished a 2 page letter to him which goes on his pillow tonight. Now I've got to get the speech right !

**DPB** · 29th April 2005, 07:35 PM

Originally Posted by Gumby

Actually it's my eldest's 21st tomorrow night so I'm a bit emotional about it all. I've just finished a 2 page letter to him which goes on his pillow tonight. Now I've got to get the speech right !

Gumby, you can't possibly be old enough to have a 21 year old. You must have started awfully young.

**Gumby** · 29th April 2005, 07:52 PM

Originally Posted by DPB

Gumby, you can't possibly be old enough to have a 21 year old. You must have started awfully young.

Don, without going into the facts of life, SHE had him, not me. She was 22 (I was 12 I think

)

**Sturdee** · 29th April 2005, 07:59 PM

Originally Posted by Gumby

She was 22 (I was 12 I think

)

I think I'll leave that aspect alone.

Congratulations and have a good evening tomorrow.

Peter.

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