Mark (TheCraftsmansPath.com) on March 8th, 2009

From a woodworkers perspective, the thing that stands out most about a sculpted rocking chair like this is probably the Maloof-style joints used to join the legs to the seat. With all of the lamination behind me, I took the plunge to start the work for this unique joinery.

squaring the seat blank 1 96x72 Sculpted Rocking Chair: Seat Joinerysquaring the seat blank 2 96x72 Sculpted Rocking Chair: Seat JoineryThe joinery starts on the seat blank.  So, I first used a sled on the table saw to trim the seat to finished length and width. The rear legs will be joined to the seat via a 3 inch by 3 inch cutout that is rabetted top and bottom on each back corner.  The front legs have a  similar configuration except they are set back from the front corners into a 2 inch wide notch in the seat.

front leg joint layour 96x72 Sculpted Rocking Chair: Seat Joineryfront leg joint rough cut 96x72 Sculpted Rocking Chair: Seat Joineryrear leg joiint rough cut 96x72 Sculpted Rocking Chair: Seat JoineryThese joints need to be very precise and with the thickness and size of the seat blank, that’s a challenge. In order to create the notches to exact size, I first laid out the joints with a pencil and then rough cut them at the band saw.  This allowed me to get very close to the lines without worrying about the precision of the joints. The rear leg notches were cut out as single blocks.  However, because the front legs are attached set back from the front corner, I used the band saw to create a series of kerfs to rough out the notches for them.

router jigs for front and rear leg joints 96x72 Sculpted Rocking Chair: Seat Joineryfront leg joint routing jig 96x72 Sculpted Rocking Chair: Seat Joineryfront leg joint 96x72 Sculpted Rocking Chair: Seat Joineryrouting rear leg joint 96x72 Sculpted Rocking Chair: Seat Joinerychiseling rear leg joint square 96x72 Sculpted Rocking Chair: Seat Joineryrear leg joint 96x72 Sculpted Rocking Chair: Seat JoineryI created a couple of jigs to help with the process of precisely finishing these notches.  In the picture you can see the front and rear leg jigs that I made to use with the router with a top bearing pattern bit.  The openings on the jigs are exactly the size of the notches to be cut and the bearing on the bit rides along the edges of the jig to trim away excess material from the joint leaving a perfect notch.  Because of the thickness of the seat, my pattern bit would not cut the entire rear leg joint in one pass. So, I first used the rear leg jig from the top and then again from the bottom to finish the joint.  After routing the rear notches, I used a sharp chisel to remove the radius left by the router bit and to square up the inside corners of the notches.

rabetting front leg joint 96x72 Sculpted Rocking Chair: Seat Joineryrabetting rear leg joint 96x72 Sculpted Rocking Chair: Seat Joinerycompleted front leg joint 96x72 Sculpted Rocking Chair: Seat Joinerycompleted rear leg joint 96x72 Sculpted Rocking Chair: Seat JoineryThe second operation for this joint was to create a rebate along both the top and bottom of each notch.  This effectively leaves a tongue in the center of each notch that will later mate with a corresoponding groove in the legs. This was done with a series of shallow passes with a 1 1/2″ by 1/2″ rabetting bit.  In the pictures you can see that I used a scrap block clamped to the outside of the seat to eliminate any tearout. The resulting rebate leaves a 3/4″ radius on the inside corners of each notch.  Later the corners of the legs will be rounded over with a corresponding 3/4″ rounding over bit to create complementary profile on the legs.

back brace routing template 96x72 Sculpted Rocking Chair: Seat Joineryrouted back brace holes 96x72 Sculpted Rocking Chair: Seat JoineryWith the joints for the front and rear legs completed I setup another jig to rout holes for the back braces where they enter the seat.  These were done with a template that I got from Hal Taylor.   The holes were routed with a 1/4″ straight bit and a 5/8″ OD collar on the router.  These holes are actually slightly oval in order to allow the back braces to flex slightly as you sit in the chair.

Next up: Leg Joinery

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5 Responses to “Sculpted Rocking Chair: Seat Joinery”

  1. Mark

    Are the holes for the back slats at an angle or perpendicular to the seat? If they are at an angle…what is the angle and how did you do make them? Your making some real progress on the project. We have seen you for awhile at the Rough Cut Forum, you may want to post that your building the great project over here on your blog.

    Chuck

  2. Hey Chuck,

    I guess I did not take enough pictures of that operation. Sorry about that.

    The brace holes are perpendicular to the seat. However they are really ovals. They were made with the template shown, a guide bushing and a 1/4″ up-cut spiral bit with the plunge router.

    The idea is that the laminated back braces will move slightly within the oval hole providing a bit of “flex” to them when sitting in the chair and thus adding some more comfort.

    I posted a bit on the original Rough Cut Forum but, I have not posted to the new one. At your urging, I’ll sign up and re-introduce myself.

    Thanks for stopping by!

    –Mark

  3. Where did you get the drawings and how did you make the seat oval holes templates?

  4. Robert,

    Thanks for visiting the blog. The plans are from Hal Taylor (see the first post in this series).

    The holes for the back slats were covered a couple of posts back – i used a router with collar in the template. The template is from Hal. He creates them with a CNC router. However it could easily be made in the shop with a router.

    –Mark

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