Man, that is a really nice project. Every time your daughters look at it, they'll think of you. It's the kind of project that gets handed off between your kids as they have kids. I really like it. How did you get the rockers to move so smoothly?
Thanks Tom. The rockers were my big worry. They have to be almost perfectly smooth to rock with out a bumping sound.
I laid the whole thing out on a 1x12 and a 1x10 dowelled and glued together. Then I screwed the two side pieces pieces together through the waste parts. (The center cut outs). I cut them out on my band saw, then placed it in my wood vice, and rasp the rockers as smooth as I could get them, then belt sanded them at the same time, so they have, if there are any faults, the same ones.
I cut out all the pieces and numbered them as per the plans
To assemble it, I put all the interior parts together, with wood screws counter sunk and glued.
A note here.. After assembling the interior pieces, you have a strange looking assembly of angles and parts.
Now is the time to plug the screw holes and sand them smooth. This would be very difficult after the whole thing is assembled.
I cut out the sheet with the plans on it, which showed how each piece went together, and assembled it to fit the plans.
I placed this sheet over one side piece of the chair and placed the interior assembly on the plans, making sure they fit perfectly.
I then placed the other side piece on top of the interior assembly, and lined it up with my framing square by going around it several times.
Once it fit perfectly, I laid out my screw lines in pencil, and carefully drilled a pilot hole through the side piece and into the interior assembly.
I marked the limits of where glue should be placed, and replaced the top side, and realigned the two sides with the framing square.
Once the top side was secured, I flipped it over, took out the sheet of paper, and went through the process of lining the two sides back up again.
Then laid out the screw lines added the glue lines and attached the second side.
I felt it was important to be sure the two sides lined up with one another perfectly or the whole thing would be off and it would never rock smoothly.
I did not have any plug cutters, so I counter sunk my screw holes at 3/8th and cut slices off a piece of dowelling, which I glued and pressed into the holes. Then I belt sanded them off smooth. As some one on the forum mentioned before. I tried to line up the grains of the plugs with the grains of the pieces so they didn't show so much, But since we decide later to paint it, it didn't matter in my case.
Another observation: By cutting both sides out at the same time and sanding the rockers and the whole out side edges of the chair while it was still screwed together. Once I had it assembled and stood it up. the feet sat perfectly with no adjustments needed and it rocked smoothly and even sat firmly on the desk side.
Damn Tom, look what you did? I wrote a book.
Sorry about that. I hope this is of help to anyone that decides to make one... MIKE??