Maloof Rocker - Shaping the Rocker Ends & Leg Transitions

After spending a few minutes rocking it was time to get back at it.  First off is to work on the front or the nose of the rockers grinding both of them to the same distance from the front of the front leg.

Nose of Rocker Ground to Length

There is quite a bit of shaping on the front of the rocker that starts with grinding the bandsawn arc into a more finished form.

Top of Rocker Nose Rough Ground to Shape

The inside and outside faces are shaped next.  I made a paper pattern so I had a better chance that both would match albeit mirror images.

Next is to grind a smooth arc on the underneath of the rocker and transition the existing radius on the rocker bottom up the just ground arc.

Last is to grind a radius on the top outside edge, transition the hard inside edge up to the leg and clean up the rough surfaces.

With the front of the rockers done it’s time to move to the back.  They are simpler to do than the front ones.  First is to mark and cut them to length.

The inside face is then marked and ground flat to make a curved taper that flairs out toward the end.

Next a similar surface is ground on the top of the rocker.

Lastly, the inside hard edge where these two grinds come together is ground to continue the existing soft radius on the rocker.

Once the ends of the rockers are done that only leaves the transitions between the rocker and the legs.  The connection angles and leg shapes are different from front to back but the process is the same for all four.  I start with my trusty French curve to layout the transition, use the angle grinder to rough out, knock off the rough edges with the pneumatic grinder, clean-up with rasps and files then finally finish shaping with the 80 grit sand paper.  The end result looks so simple and obvious yet the time and effort to get to there really adds up.

Transitions from Legs to Rockers Completed

With that done I can move on to the final sanding and finishing, or maybe not.  There are two items that still need to be dealt with.  First, as I sat in the rocker testing it out I found that the arc at the front edge of the seat was a little sharp and needed softening.  I could not just leave it so I drew some guide lines and started in with the usual implements of destruction; pneumatic grinder, rasps, 80 and 120 grit sandpaper.   I am happy to say the front edge is now easier on the back of my legs and I can get on with the final sanding of that area. 

Second, is that #!@% flaw in the seat that I am going to have to address.  However, I still do not know what I am going to do with it.  Perhaps as I do the finish sanding I will have a moment of enlightenment.  Still at this point I am happy with what I have done so far.

Next up – Final Sanding & Flaw Repair