Rockers and legs
Fine turning the look of the rockers was a breeze. A good sharp flat spokeshave takes care of 90% of the work. Rasps do the rest. Again, another area of the build where you can do whatever floats your boat. The bottoms of the rockers I left alone. I like the idea of a good size flat for the rocker to rock on. I also think this gives the rocker a bit more lateral stability? Don't know that to be a fact, but works for me...
The tops I tapered a good bit to take advantage of the laminate buildup. Starting out slowly and then working into a groove, the rockers shaped up in no time. I just love the sound of a sharp iron cutting thru the wood. Curly little shavings all over the floor. Ahhh ya gotta love it
Using the maple portion of the laminate as a reference, it wasn't hard to keep both sides balanced
I shaved the back tips down to a nice taper and rounded off the ends. A nice clean look. Visually, this is or can be a very important part of the build. I was pleasantly taken aback by just how much of an impact the rockers have on the over all look. The wife came down to see how things were going and first thing she said was "Wow".."that really looks nice. And you all know when the wife approves, your in good shape...*L* I shaved off as much as I could for now. The remainder will be cleaned up as part of the shaping of the risers.
Next was to set the chair to the rockers. This part of the build is perhaps the most demanding in terms of having to get it right. There isn't much room for OOOPPPSS.
First off, I'm setting the rocker back further than plans dictate by 1". I'm doing this to get more of the laminate to pop on the front tips. Not a big deal.. just another personnel preference thing. Setting the rocker atop of the rockers can be a little trickly. You just got to be careful to not tip the rocker. At this point, the rocker has a bit of weight to it. You also want to do this part of the assembly on a "flat" surface. Since my workbench is anything but flat it pays to have a nice sized piece of MDF sitting around. Usually I'd use my router table as an assembly table, but the rocker sits too high.
Long story short, put the MDF on the workbench, laid out the rockers and got the chair atop of them. I then ran a piece of wood overtop of the rockers to secure then down. Got the chair positioned where I want her and laid out a few lines. Laying out the position of the leg is important. In doing so, you can then take the rockers back to the vise or the bandsaw and remove most of the waste from the risers as needed.
Next is to get the legs to sit flush atop of the risers. The front legs had about a 1/8" gap on the back side and the back legs had a little less than 3/32" gap in the front/sides. Now at this point you could take a scribe and mark out each leg to riser joint, remove the chair and clean things up like that. Or you can take a piece of low grit sandpaper (preferably cloth backed, which I didn't have any of), place the sandpaper face up between the leg and the rise, and pull the sand paper thru. By doing this repeatedly, you sand down the leg and eventually end up with a perfect fit. Keeping in mind, that while you are doing this, to pull downwards on the sandpaper as you pull it thru. Otherwise, you'll crown the bottom of the leg. 15 minutes or so with each front leg and I was walkin' in tall cotton.
This little sand paper trick worked beautifully. I'll do the same with the back legs, then go over all 4 once more just to tweak things out.
Pic 276: Rear tips of the rockers. Rocker on the right is done. This is the beauty of doing laminate work. Now, with this maple showing as it does, it helps pull in the maple from the armrests a little.. not much. .but a little...
Pic 277: Side view of the rear tips
Pic 278: Rear tips again.. a little finish work and these ought to pop nicely.
Pic 279: Beginning the laying out of the legs to the rocker/risers. Take time here and get it right. By laying out now, you can remove the rockers to the bench or band saw and remove most of the riser waste ahead of mounting permanently.
Pic 280: Laying out the rear leg. The angle of the legs to the risers is a bit skewed by design. Shaping of the leg/riser joint should (?) take care of any visual issues...
Pic 281: By placing a piece of sand paper face up, under the leg, then repeatedly pulling the sand paper thru the joint, you get a flush joint. Sweet!!! I came across this idea doing research work on this build and couldn't wait to give it a try. Dang if it didn't work ;0
Pic 282: This pic gives you an idea of the gap in the back of the front legs. About a full 1/8".
Pic 283: This is the joint after doing the sand paper trick. I'll do this to all four legs, then go back and do them once more for a fine tuning. Changing the mounting angles on the back legs will change the angles on the front legs by just a hair. Might as well take a few extra minutes and do them again and move on from there..