charlie b said:

BobS wrote:

Greg,

Unless I'm missing something, why not just mill some stock wide and thick
enough to make the 7 slats from. Make a template, transfer it to the stock
7 times, then start cutting on the bandsaw. The stock would be flat (laying
on the edge side of the slats) and you just follow near the cut line.
Finish them up on a spindle sander.

Bob S.

Well first, 1 1/2 1o 2" thick walnut .ain't easy to come by for a lot
of folks - though not a problem for Mr. Maloof who can have half his
original stock become cutoffs and scrap.

Boy, you've got that part right. $2000 for a rocker and I could
afford to throw out half my stock as well. I'm so poor, I have to cut
down cherry trees in my yard for lumber - and then wait 3 years to use
what hasn't split. ;-)

Second, the first bandsaw cuts do the "S" curve then you have to put
those back to make the next cuts for the curve to go from flat to
round where they go into the chair seat and chair back.

Well, I'm not trying to emulate his work, I just saw that his design
has the same style of slat as my design. I can deal with differences.

And still photos don't even hint at what his video shows. 2-D stills
just don't convey how he sculpts on the bandsaw, hitting two lines
on adjacent faces which are both curved. It's pretty amazing to
see - and a bit scary. Freehanding with only one contact point on
the table is a touchy process. One hidden knot or hard spot, a tooth
catches rather than cuts and the end he's holding comes down very
quickly, with a lot of force, onto the unyielding cast iron table.
If you think a catch when turning is "interesting", try one on a
bandsaw - while free handing

That's for sure. I've seen a video of him working, and I now
understand why he has several missing fingertips. I was a complete
novice when I saw him freehanding a rail on the bandsaw and freaked.
And no, I didn't try if for myself, and probably never will. I prefer
jigs and other "disposable" objects to be shredded by a fast moving
blade as opposed to my most valued body parts. Nothing that endangers
my fingers, hands or eyes. I'd rather loose Mr. Winkey!

Oh- the special router bits he had custom made for the back and
arms to the chair seat joints are now available to the rest of
us.

And where would that be? Whiteside? Amana?
I've often wondered how he did those, thinking perhaps through hours
and hours of sanding - but apparently not.


Greg G.