Monthly Archives: January 2013

SAW Butt Joint Table Top

Another table top for SAW. This top features three of the five sections of lumber being butted together in order to create the final 60″ length. This type of construction requires some thought and planning to execute well and create tight joints both along the edge grain and at the end grain. There is also the consideration of where those butt joints occur. I set up the middle two board’s joint to occur at the center point. The two adjoining joints are evenly measured off that point and creates a step look that is mirrored when viewed from the other side of the table.

SawyerButtJointTop

Rocker Arm Build

The arms require stock that is 10/4 or 2 1/2″ thick in order to create the deep sweep shaping. Only having 8/4 lumber, I needed to re-saw and glue up the appropriate thickness stock. Once milled, the layout and cutting were simply done on the band saw. A corresponding dowel hole was drilled to create the joint between the front leg and arm. The back leg connection is a glue/screw joint.

RockerArms

Rocker Back Leg Profile

A continuation of the back leg construction. This process removed a bulk of material around the leg to seat joint by cutting a radius to connect the sweep of the leg to the top of the seat.

RockerBackLegProfileShaping

Rocker Arm Lumber Blank Re-saw Video

In order to create an arm with a deep sweeping profile and also meet the front leg and back leg joints, the stock needed to be 2 1/2″ thick or 10/4. The boards I purchased were only 8/4 requiring me to do a glue up to achieve the appropriate thickness. Instead of gluing two, 2″ thick boards together and cutting off a lot of waste, I decided to cut into one of my 10″+ boards to create 4, 5″ wide pieces. I then re-sawed them using the table saw to 1 5/16″. The picture gallery the will be posted next shows them being glued up and then jointed and planed to 2 1/2″. The arms are also book matched, meaning the two blanks were originally connected across their width as one 10″ wide board. Enjoy.

Rocker Back Leg Joinery

The previous back leg post ended at the rough blanks being cut out of the bigger stock of lumber. This gallery picks up with the flush trim routing to the leg pattern. Then adder blocks must be milled and glued on to accommodate the angle that occurs at the seat to back leg joint. Once they are added and squared, layout of the mortise joinery occurs. After the table saw, the inside corner must be rounded over on the router table. The next update will begin with the fine tuning of the round over.

RockerBackLegJoinery

Rocker Back Leg Front Profile Video

Here you can watch as the front profile is cut for the back legs of the current rocking chair build. The picture gallery will be posted tomorrow and follows the layout of the profile before cutting and the legs after they are cut. The legs will still need to be finish shaped before final assembly.

Rocker Front Leg Lathe Turning Video

This is the video of the rocker front legs being turned on the lathe. Thanks to Phil Gautreau, resident turner at 3rd Ward, for filming and getting me set up on the lathe after a seven-year hiatus.

Rocker Front Legs On The Lathe

This rocker gallery update follows the process of putting the legs on the lathe to turn them. The legs are tapered from the joinery area to where they will eventually attach to the rocker and arm rest. This was the first time I have been on a lathe in about seven years. I forgot how much fun it is and what a relaxing experience it can be. A video update will be posted above.

RockerFrontLegTurning

Circle Router Jig Video

This video was shot during the SAW table top build and shows the circle plunge router jig in action. The jig itself is made of 1/4″ thick acrylic and fit specifically for the Milwaukee plunge router seen here. The jig works by measuring the radius of the circle from the inside edge of the bit you are using and drilling a hole to send a screw into the bottom of your circle. Then you are able to plunge into the wood and work around the circle. This works best if you have already drawn out your diameter in pencil and band saw close to that line so you only have to remove about 1/8″ or less of material.

SAW Table Top Builds

This gallery contains images of the build process of four table tops for SAW. SAW combines predominately metal base structure with wooden tops and drawers. SAW is also run out 3rd Ward‘s space, specifically the metal shop. This build called for a router jig to be made in order to create the perfect diameter cut for the circular table top. Video of that jig in action will be posted shortly.

SawyerTable1

Seven36 Fine Woodworking LLC

Custom Woodworking Company