Challenges with Maloof on your back – FineWoodworking

My present challenge is to remake a Maloof chair with a low again. I made one in every of these in 2010 utilizing silver maple, however this time I wish to use an previous Modesto ash board. For a lot of its life, this board has been uncovered to the weather and bugs. It was initially reduce about 15 years in the past on the native sawmill. Most of our Windsor chairs use this materials – it is robust and bends properly. Right here is a photograph of the unique chair I made, together with a photograph of the ash plank.

Right here is the ash plank, over 2 inches thick and principally sawn off. It held its form very properly. Sadly that is my final piece and so I have to produce all the mandatory elements for a chair.

In 2010, I developed the challenge utilizing SketchUp, so I am utilizing this useful resource accessible and necessary. Right here is the mannequin assembled in SketchUp. Be aware that I did not develop the ultimate sculpture of the chair elements in SketchUp, simply the tough sawn shapes.

One of many first actions within the constructing course of is to create the full-size fashions. As all elements of this chair are advanced shapes, fashions are the important thing to success. Here’s a view of the association of jigs to assist with the mandatory cuts within the ash plank. I am discovering that I am restricted to simply extracting the mandatory elements from the chair, however there will not be sufficient for alternative elements.

All elements of the chair had been molded on two axes – the aspect view and the highest view. This doubled the variety of full-size fashions wanted. Right here is a photograph of the tough bandsaw elements (no joinery but).

Along with the 2 primary fashions, some elements additionally benefited from a “flat” full-size mannequin. As you possibly can see on this subsequent photograph, the higher arm template is positioned on prime of the curved higher arm face. This “flattened” template is longer to suit the curved floor and permits exact marking of the form reduce within the vertical dimension. There are a number of plug-ins accessible within the SketchUp Extension Warehouse that produce these “flat” fashions. Using a flattened jig was additionally very useful in laying out and sawing the hind legs.

Right here is a photograph of the present state of development, dry-fit mounted.

There may be much more work to do as not one of the sculptures had been made. Collage is subsequent, then sculpture.

I ready movies of the development course of. Here is the beginning video for that playlist.

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Extra from Tim Killen