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Woodworking

By

David Peterson

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Sam Maloof Style rocker made from walnut, maple, and ebony.

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The rockers are made as a glue laminate with alternating layers of walnut, maple, and ebony. Laminate adhesive was Titebond II

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Sam Maloof invented some unique joining techniques to build his world famous rocker design.

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Almost every surface is carved or custom shaped to some degree.

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Rocker construction involves a lot of carving to obtain the graceful final shape. But unique joinery is key to the creation of the Sam Maloof rocker.

1-1/2” rabbet bit with ½” guide wheel to form curved seat joint

Trim front leg to perfect fit into rabbet.

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Cut ½” deep rabbets on 3 dies of front leg for perfect fit into rabbeted seat.

Radius inside edges of front leg with 3/4” round over bit.

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Other steps unique to a Sam Maloof rocker include

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  • Glue lamination of the rockers using alternative wood types.

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  • Extensive carving to create the seat profile, transitions between the seat and legs, the arms, and the transition between the legs and rockers.

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  • Anyone who wants to build a Sam Maloof rocker should consider getting plans and video instructions from Charles Brock.

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  • charlesbrockchairmaker.com

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  • This is another example of glue laminate work. Conference table is made from figured maple with walnut inlays and walnut screw plugs.

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  • One of the legs clamped in place on the on the fixture.

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  • Laminate adhesive was Unibond 800. Titebond II works just as well.

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Finish is three coats of hand applied polyurethane

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More laminate bending. This side table is made from bubinga and yellow heart with ebony screw plugs.

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Dining room sideboard made from walnut

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My first use of wood hinges circa 1993.

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Recently completed curved front dresser made from walnut, figured maple, yellow heart, and wenge.

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Walnut hinges

Wenge inlays

Walnut, wenge and yellow heart pulls

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The magic of figuring is due to crooked grain structure.

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The downside of figuring is the material is very hard to machine without producing divots.

Grain direction

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Bedside table made from figured maple and walnut.

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Whimsical armoire with walnut framing, figured maple panels, and wenge inlays.

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  • Pulls are made from wenge, walnut and yellow heart.
  • Wood hinges are made from walnut.

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Customer didn’t like the original finials. Replacements were made from wenge, walnut , and yellow heart.

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Small writing desk made from highly figured maple with ebony inlays.

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Two drawer chest made with walnut framing and figured maple for panels top, and drawer fronts. The legs are splayed 2.5 degrees side to side and front to back. The top has a large overhang and is beveled on the bottom.

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Pair of side tables with walnut legs, figured maple top and wenge inlays. Legs flair 2.5 degrees to add interest and stability.

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Carom board project with walnut frame, quilted maple corners, and birch plywood playing surface.

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Combination padlock made for my father- in-law. Back opened so he could see how it worked.