Step 1: Selecting the Wood
Color matching & grain direction are very important when we build any of our pieces furniture. The intent of the Rocking Chair is to make it look like its all been carved out of one piece of wood & making sure the grain direction flows properly; with the grains following the same direction as possible. At the joints or extreme bends the wood will be free of any flaws. Sometimes when cutting out the chair this results in not being able to perfectly color match the wood but this does let us keep the integrity of the chair insuring that it will last for generations.
Step 2: Cutting out the wood
Once the wood is selected the parts are laid out and cut (if its a piece of furniture we have built before we use out templates) Each part is then cut with the appropriate tool & sized to the exact dimension.
Step 3: Joining & Assembly
After each part is cut to the right size, we then shape it and create the joints were necessary. We dry fit each joint insuring a exact fit. Most of our joints are glues & screwed together occasionally using dowels to establish a strong joint. Most part of the chair are assembled, taken apart, sanded, assembled again, taken apart again and sanded again (sometimes this process is repeated several times but is necessary to create a fine piece of furniture) .After the chair is glued together & has dried completely we then carve many of the parts into each other. This is where the soul of the chair & it is brought out; carving, sanding & filing brings our chairs to life.
Step 4: Finish Sanding
Each piece of furniture is sanded to 400 grit this really brings out the grain & gives each chair character. This is the part in the process where I see myself staying late at night loosing track of time because I find it so much fun and rewarding. I see each piece of furniture come to life & it is really one of the greatest parts of what I do.
Step 5: Finishing
We are able to apply several different types of finish like tung oils, lacquers & conversion varnishs. This is depending on what piece of furniture it is and the abuse that it might be taking.
"The backs of our chairs are all laminated &
shaped; this allows each chair to give
extreme lumbar support, making the chair very comfortable. " - LaMar Herget
