The rockers for the chair are laminated from 10 layers which are 1/8" thick each. This yields a rocker thickness of 1 1/4", the width of the rocker laminations is 1 1/2". First the laminations are pressed against a form and let to cure. When that is done an additional 7 layers are built up where the legs join to the rockers. Once the rockers are completely laminated one of the edges is jointed and the rocker is thicknessed down to 1 1/4".
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| Laminating the Rocker on the Form |
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| Adding on the Extra Layers Where the Feet Join the Rocker |
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| Jointing One Side of the Rocker |
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| Thicknessing the Rocker |
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| Thicknessed and Ready for Installation and Shaping |
With the dimensions squared up at 1 1/4" a router with a 5/8" roundover
bit is run over the edges so that the rockers are now a 1 1/4" diameter
tube. This tube is lightly faired with sand paper and then installed
using epoxy and dowels similar to how the front of the arm rests were
installed.
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| Rounding Over the Rockers |
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| The Rocker Rounded and Ready for Installation |
The location and angle to drill the dowel holes is done in two steps similar to the installation of the armrests. The holes are then drilled on the drill press using a wooden screw clamp to provide extra support to the curved piece.
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| Marking the Drilling Locations for the Dowels |
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| Marking the Drilling Angle for the Dowels |
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| Epoxying the Rockers in Place with Dowels |
Once the holes in the rockers and legs are filled with epoxy a set of clamps is used and left overnight.
I'm sorry that this project has taken so long to write up, it keeps getting interrupted. My hope it to have one more post about the rocker and finish off the project.
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