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First off you are probably going to say "shouldn't the name of this project be a "Windsor Rocking Chair"? Well before you get too excited and let this project scare you away, we are only making the rockers for an existing chair. We had a swivel rocker that didn't fit well in our house so we gave it away but were left with nothing to rock on. Marilyn's sister Susie especially likes to rock when she comes to visit. We had a really nice Windsor chair that would fit the ticket perfectly if it only had rockers.
At first glance this looked like a pretty simple project but as you'll see there is quite a bit to it.
Here's what you'll need:
The very first thing to do is decide how long your rockers will be. Our rockers are 31" long.
It's best if you can find a string that doesn't have too much stretch. Hold the string steady and lay out your lines.
Mark a line on the side of the rocker in line with the leg.
Now use the T-Bevel Sliding Square to align the drill and using a Forstner bit drill a hole to accommodate the chair leg.
You will be drilling in two directions. Be careful to start the bit into the wood a little bit before you crank in your angles.
Apply double back tape on the MDF pattern.
Attach the pattern to the rocker and run it against a bottom bearing flush trim bit. You will have to make two passes unless you have a really long bit and powerful router.
Since the grain on the wood will be going the wrong way for your router you will need to CAREFULLY do shallow "climb cuts" to prevent tear out. This means to go with the rotation of the router instead of against it like you are supposed to. Make shallow cuts and hold onto the wood really good and you should do OK. This is not a recommended way to run you router and I take no responsibility for any issues you may have doing a climb cut. The good news is it sure beats the alternative.
If your bit is not long enough make your first pass, remove the MDF and make a second pass.
Sand the sides smooth and you should be ready for finishing. Our picture at the beginning of this project does not have the rockers finished. I wanted them to stand out so you can see them. Once the finish is applied screw the rockers on to the legs, sit back and enjoy! I did not glue the rockers onto the chair because I may want to remove them some day.
That's about it. We hope you liked this project. If you build it and your friends ask where you got such a clever idea, please tell them that you got it at RunnerDuck.com.
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This is what it looks like: