charlie,

Agreed, finding some 8/4 walnut may be difficult but not impossible by any
means - if that's what he's using but the OP didn't say anything about using
walnut.

I disagree about having to tape the "S" curved slats back together to cut
the transitions for the rounds. No matter whether he laminates them or cuts
from solid stock, they still need to be cut. Simply lay the slat flat on
the BS table and make the cuts - one at a time then do the final rounding
with a rasp and sanding.

As for free-handing on the bandsaw, I don't see where any single-point
free-handing is necessary to make the slats - look at one of Maloof's
rockers and I think you would agree. Whether he laminates the slats or makes
them from solid stock, the transitions for the rounds still need to be cut.
Simply laying the slat, flat on the BS table and making the cuts will get
the job done. Then, as Mr. Maloof does, he gets out his rasps, files and
then has assistants sand them for a week or two.

I don't think there's as much waste as one might think in making the slats.
If someone is making a heirloom piece out of a fine hardwood, then a few
extra dollars isn't really going to make a difference in the overall price.
I would bet that someone making laminations for the first time like these,
would waste more wood than making them out of solid stock to begin with.

As Greg stated, he did a lot of research so I imagine he came across the
many sites that show Maloof inspired rockers and although some used flat
slats, top to bottom, others made the slats similar to Maloof's. This type
of rocker is not made primarily with a tablesaw and as such requires a
person skilled or at least willing to learn how to use a bandsaw. I consider
my 1hp bandsaw a lot less dangerous than my 3hp tablesaw and certainly a
versatile tool.

I'm no expert on it but if there's a difficult piece to make, it's usually a
good fit for the bandsaw. Leave enough spare stock at the end so you can
handle the piece safely if you're free-handing it. Go slow enough so that
when you make a curved cut the blade has time to cut and you're not putting
a lateral load on the blade causing it to deflect, bind and then grab the
wood out of your hand. Also be sure your table is large enough.

There's several methods he can use to make these, from steam bending, cold
laminations, template and router to cutting them on the bandsaw. The
bandsaw appears to be the most effective method and certainly not the most
expensive when you consider what it takes to make the slats using other
methods.

Learn a new technique, practice it using scraps until your comfortable with
the whole process and do it safely - then go for the gold. It's called
woodworking.

Bob S.


"charlie b" wrote in message
...
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.

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.

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

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.

charlie b