Anna Rocker Build

So I haven't been blogging for a while, but I have another long distance customer and its a good way to keep them up to date. This project is a Mid Century inspired rocking chair for Anna and her new arrival Matilda. This has been going on for quite some time with design work, fitting, and a full size prototype. That first version is at the upholsterer right now and should be done soon! My upholsterer David at http://www.remnantsdesign.com/ is the best. He specializes in exactly what we're doing here.

                     Here is a photo of version 1, sans upholstery.

The final version of the chair will have splined miter joints where the arm legs meet the rocker and the arm. The back leg will also kick out a bit further toward the rear.

The rockers are the first thing, since the 7 layer lamination takes 24 hours to dry for each. I rip 1/4" strips off a board, keeping them in order the way they came off. Next I run the strips through the wide belt sander, removing the bandsaw marks. I put the stack back together, and prepare my glue. I use Unibond 800 for laminations because of its very rigid glue line. I roll glue on with a foam paint roller, stack them up in order. I finally found a perfect use for these goofy clamps I bought on auction a while back. They don't slide off when used on a curved surface!

Once the glue is cured, I joint one edge, then run the other side through the planer. I'll set these aside till I'm ready to cut the miters on the ends.
Next, I started milling the 3 rift ash boards, then used my patterns to select the grain I want for each part. I rough cut each part on the bandsaw. Then its on to joinery. 


I'm going to do the bridle joints on the back legs first. I cut the angle on the ends of the four parts on the sliding table saw. Next I machine the mortise on the Multirouter. I make test cuts so I get it perfectly centered. Then I use mortise to set the cutter height for the tenon. Once I cut one cheek away, I've lost the reference to the fence on the machine for the other side. I milled up a piece the exact same size as the length of the tenon to use to set the piece up for the other side. Forgot to get a picture of that. It worked great though. I dry fit the joint, and its a bit tight. Couple swipes with the Clifton plane and its right where I want it. This is a difficult joint to glue up, like a boomerang in two parts. I've decided to add glue blocks to each face so I can clamp in the right direction.

Once that glue has set up about half an hour, I go ahead and glue up the leg joint. Awesome, squeeze out all around.

I leave that clamped for an hour or so. Then I have to cut and plane off those glue blocks. It was a pain, but the result was worth it. Perfect joints. Next I'll be cutting and smoothing the leg to final shape.