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Group
Woodworking classes
Code # 20
Build Grandpa's rocker in the Maloof
style
Start a new business or upgrade
one. No expensive tools needed or
even a Table Saw required.
The above rocker is a “Classic” in the Sam Maloof
style.
See samples rockers for ides of
what you can do under rockers in the gallery.
I will show you all you need to know about
making these rocking chairs. Any woodworker can do it!
lpelusa.com
code #
20 DATES
FOR 2010
Group class Dates:
March 22-26 (closed); April
12-16 (closed); April 26-30
(closed);
May 24-28 (closed)
June 21-25 (closed)
July 26-30 (closed)
August 23-27
September 20-24
October 11-15
Limited four (4) to ten (10) students per class
See a student’s posting to ‘Lumberjocks’ with pictures
during his class week. (at bottom of page)
I will
demonstrate each critical step in making a Sam Maloof style custom
rocking chair including the unique joints. You will learn it all; even
the shop secrets.
You will receive
a complete instruction manual or credit if you have already purchased
one. Hundreds of pictures available, also a CD loaded with pictures.
You will
be able to copy the shop built jigs I use.
You can
take all the pictures you want for your personal use.
You can
cut hard copies of other rocker and chair part patterns I use and or make
paper patterns.
It is not
necessary that you be an accomplished woodworker because I will show you how
to build a custom rocker using a few economical tools. Even a table saw
in not necessary and the rest of the tools need not be the expensive
variety.
One of my
most handy tools was a free gift I received at one of the woodworking
shows.
The jigs
I use are rough, scrap lumber, shop built things taking only a few
minutes to make.
If you
follow the instructions I give you will be able to make a custom rocker
with accurate joints, ideal balance and custom sized. When you leave my
shop you will have been exposed to all the techniques necessary to build
a custom rocking chair.
Group Seminar Cost:
Four
day seminars cost $1,100. A two hundred seventy-five dollar ($275)
deposit will reserve a spot for any open seminar. The balance of the seminar fee is
required on or prior to the first day of the seminar. If for some reason
you cannot make your date the deposit can be applied to another date or a
manual.
Snacks and drinks will be provided each day of the
seminar, but meals and sleeping accommodations are your responsibility.
About Utah & Ephraim:
My shop is in Ephraim (about 5 thousand
population), Utah, and only about two
hours South of the Salt Lake
City international airport. We are about fifty-five hundred feet above sea level in a
beautiful mountain valley.
Recreation:
There are several golf courses within minutes of my shop. Racket or
handball, basketball etc. facilities at Snow College
just blocks from my shop. Bowling at Snow Cap Lanes two blocks away.
Fishing galore in more than twenty lakes and streams within minutes of my
shop. ATV (rentals available) trails all over the place with miles and
miles of mountain adventure available.
Summer
Recreation Sanpete County: Hunting; Fishing; Camping; Golfing; Festivals;
Rock Climbing, Track Elk herds on horseback, Visit State and Federal
Parks, Museums, Art and Antique Shows, (visit www.sanpete.com for more
information)
May:
Scouting Expo, Rhubarb Festival, Soap Box Derby;
Spring City Heritage Days; Ephraim Scandinavian
Days; Memorial Day; Big Daddy Roth Days;
June:
Fly-in for "plane nuts"; Old Home Days; Mormon Miracle Pageant;
Heritage Days; Hub City Day with muzzleloader shoots, 'mutton bustin';
rodeo; Golf Tournament etc,
July:
Mountain Man Rendezvous; Lace Days; Blackhawk Rendezvous; Children's
Theatre; Pioneer Days; Ox burro Rodeo; Softball tournament; ATV rodeo;
August:
Mountain ATV Run; GBEEC Star Party with Snow College Physics Dept.;
Backcountry first aid workshop; Sanpete County Fair; Arts Plain Air Competition
(art work will be for sale). Classic Bike Race with 46, 75, and 102 mile
races on courses that wind through the local countryside with little
traffic.
September
: Arts Festival and Artist' Studio Tour; Sanpete County Cruise-In
and Poker Run;
October :
Apple days start with Ugly Witch Contest and parade;
December
: Old fashion Christmas
Village
Hotel Accommodations:
Hotel accommodations are within a few
minutes of my shop.
Hotels in
the Ephraim area:
Willow
Creek Inn, 450 S Main St, Ephraim, UT
(435) 283-4566
Temple
View Lodge, 260 E 400 N, Manti, UT
(435) 835-6663
Manti
Motel, 445 N Main St,
Manti, UT
(435) 835-8533
Manti County
Village Motel, 134 N, Main
St, Manti, UT
(435) 835-9300
You Build- CLASS: code # 21
One-on-one (you build) classes please call for
a date of your choice.
"You Build" (Seminar Rocker) If you
prefer to make your own rocker (You-Build) I will give the personal
(one-on-one) attention necessary while we construct your rocker (about
one week). I supply the wood of your choice (so long as it is not toxic),
all information, tools, patterns, jigs, shop space, adhesives and snacks.
This includes the accent materials such as Ivory, Ebony, Bastogne, African
Blackwood, Burled Mesquite etc. When you take your rocker home it will
still need to be finish sanded and detailed using my supplied finish and
instructions. For Mesquite
wood the cost is $4,500 for the seminar help, wood etc. If you choose an
exotic species of wood the cost will have to be adjusted . This is the
best way to receive personal instructions, manual, jigs, etc and obtain a
rocker. You can keep the rocker or sell this rocker at a profit to pay
for the class. You end up with the ability to make custom rockers for
free. For the "You-Build seminar rocker" please contact me
about any week of the year. Code # 21 for "You-Build seminar
rocker" info. Email me or give me a call if you have questions.
bill@kappelusa.com OR call 435-283-3193.
A two hundred
dollar deposit will hold the date you choose. The balance is due the
first day of class.
One of the best parts of building a rocker in Utah is the dry climate of about 5
percent. You can take the rocker anywhere and be confident your work will
stay sound and durable. If you build a solid wooden rocker in any humid
climate such as on the East Cost and bring it out west it will dry to our
local moisture content and likely crack and the joints will loosen. Solid
wood moves with moisture content and that is the reality of the matter.
Even if the lumber is kiln dried to the 6 to 8 percent ideal, in high
humid areas most shops will re-acclimate the lumber in a few days to a
much higher moisture content. We have all heard of the horror stories of
families moving from Florida to some
western state such as Arizona
or Nevada
and have their solid wood furniture fall apart.
Semi-Built Rocker Code # 23
Semi Rocker: If you would like me to semi complete a rocker the cost
is $3,300 for White Oak plus packaging & freight. Or add the cost of
some exotic wood species you choose. You receive an assembled rocker plus
the Backslats and Headrest parts plus the instruction manual. l will
rough cut and assembled the rocker except for the Headrest and Backslats.
You finish the rocker by shaping in the arm, leg and Headrest joints,
then finish sanding. The Headrest and slats will have to be mounted after
you finish sanding them. My instructions will give complete details about
how to mount the Backslats and Headrest. The Backslat holes are drilled
in the seat and Headrest. The Backslats will be sized with the tenon for
both ends cut. The Headrest will be pre-fitted to the legs and Backslats,
but will need to be sanded and glued in place. This is a good way to get
a new rocker and still have the pride of your own work. call
(435-283-3193) or email bill@kappelusa.com Code # 23 for semi
rocker info.
Rocker Kits---Build
Grandpa's Rocker Code # 22
Kit
parts: I will rough cut all the part for a custom rocker in the
Maloof style. The full instruction manual with patterns. and colored
pictures, to finish the rocker will be included, as well as lots of
pictures on a CD. The cost for Mesquite wood is $850 + packaging &
freight.
Until
stock lasts I have some Claro and Bastogne
walnut, from the same stock Sam Maloof was shipped recently, which I will
be selling for $2,500 for the cut kit parts. Code # 22 for kit
info.
The
pictured rocker is made with Bastogne
walnut. The kit rocker can be made in this style or others. If
accents, such as, Ivory, Ebony, Maple, Myrtle etc. are wanted they can be
provided with applicable instructions for a small additional charge.
Proprietary instruction Manual:
Code # 25
Instruction
manual has Rocking Chair patterns: with
lots of pictures, also a CD with loads of pictures, paper patterns, shop
jig info, pages of detailed instructions so you can build a custom rocker
of your own choosing. This information is not for a cookie-cutter
style rocker. The details are such you will be able to make any
style rocker on the market or make one of your own design. I
have included special instructions for upscale rockers I have not seen in
any other offer on the market today. If you buy a manual and later
take a seminar, the cost of the manual will be applied to the seminar. Ask
any of the thousands who have received my (free info) if this is not good
stuff. If the free info is good you can imagine how good this full manual
is. $150 use Code #25
New Free
text, Code # 2BBB
Free information on how to build a custom rocking chair.
This is not a cookie cutter rocker you will be building, but a custom
personalized rocker.
There are almost 40
pages of detailed instructions giving all the information necessary to
make a Sam Maloof style rocking chair project. The info include jigs I
use with shop secrets. This material is the draft, less the three
ring binder, full size patterns, upgrades and additional pictures, I
used to create my full text manual included in my seminars and sent
with each rocker kit. This info will be sent by email. Send me the code #
posted to bill@kappelusa.com I can then attach the file. The code #
changes often so be sure to use the correct code #.
This is a trade-off.
You visit my web site and I will send the free info. If you want the
added extra upgraded 'draft' info just send $25 dollars and you get all
the bits and pieces with pictures left out of the free stuff. If you want
the full text with all the professional up grades, pictures, patterns,
binder and CD with more pictures the cost is $150
I will be glad to
help all woodworkers, if you like what you see feel free to post the
offer to any other woodworking forum. They should do a Google
search for "kappel rocker' or go to my web site at
kappelusa.com then make their request.
Please use the applicable Code # in your email
subject line when referring to your inquiry so I know it is not junk
mail.
A student’s week at one of my classes
The beginning of “old
guy” summer camp started today and my fine camp counselor is a true
gentleman named Bill Kappel. I finally found the perfect thing to do with
my extra week of vacation this year. I went to rocking chair camp.
For those of you who
don’t know of Bill Kappel, he is also known as the rocking chair
guy. He makes his own take on the Maloof style rocking chair and does it
with style and class. Not only does he make chairs and other amazing wood
pieces, but he also offers classes ranging from one on one to small groups.
He is a great guy, and I feel fortunate to be working with him this week.
You can tell he is good since unlike some hacks I know, Bill laughs at
the concept of being called a master woodworker. (even though he just
might be one)
For me it was a cross country
trek since his workshop is a bit more than 2 hours South of Salt Lake
City Utah in a place called Ephraim. I am not sure how to pronounce it,
but here I am in my hotel room writing this blog entry. I live in Cleveland, Ohio
when I am not traveling so Utah
is a big change of environment for me.
Enough fluff.. lets talk
about the build. Today was day one and we started making the seat. I
chose Mesquite
lumber for my chair, and I have to say the figure is amazing. Bill has an
amazingly organized and intelligent method of building his chairs that
can be broken down into specific and orderly steps. The advice he offers
at each step helps understand how the choices are made for each step in
the process. He follows a similar procedure to the one I have seen on the
Maloof DVD I have, but obviously hands on is the way for me to learn it.
I will take pictures and
post them as the days go on. I am also making some video recordings of
technique so that I can refer to them when I need to make my next chair.
Today was day one and I have several to go. I am confident that when I am
done, I will be taking home the best looking chair in my house.
I will keep you posted.
Day 2 started with taking my glued up seat out of
the clamps and taking my first shot at carving out the seat with a
grinder. I have not done this before so it took me a bit to get the
technique down. It will take far longer to perfect it.
I was fortunate to have
Bill’s undivided attention and patience. He helped me get the
angles right until I started to get my seat formed. Had I tried to learn
this on my own, I guarantee that I would have wasted dome prime lumber
until I got to this point.
This so far has been an
extremely interesting and educational experience. I am sure it will
continue this way.
Well, day 3 has ended and man am I tired. It was a
super productive day.
The legs were formed and
fitted. The biggest challenge was to mate the legs to the seat.
After hours of fiddling and
using Bill’s method, all was fit perfectly. What a thrill to see
the legs attached and fitting like a glove. After the legs were fit, Bill
gave me another lesson in machine carving to form one back leg to the
seat. Later we cur out both arms and carved the first to fit.
 
front leg is marked
band saw cut after offs
 
a close up on the
joint back leg is cut out
 
grinding a joint
 
leveling and sanding legs dry fitted
 
arm blanks were doweled and dry fit
 
cutting away waste on the band saw
part two of many cuts
 
carved out arm
leveled and rough sanded
arm
done for the day… tomorrow is more
Today, we did more
sculpting, cut and glued up the laminates for the rocker runners, and
created the headrest and the first back slat. The following pictures tell
the tale.
 
head rest blank is fit to back legs head rest first cuts
 
sculpting the head rest finished
shaping
 
holes drilled for back slats testing first back slat
 
bending the rails marked to sculpt
roughly sculpted
More tomorrow… only 1
and a half days to go.
The biggest challenge here
is that I can’t actually finish the whole chair. I will UPS myself
the components and when I arrive home do final gluing, shaping, sanding
and finishing..
More tomorrow
 
head rest blank is fit to back legs
head rest first cuts
 
sculpting the head rest
finished shaping
 
holes drilled for back slats
testing first back slat
… only 1 and a half days to go.
Tomorrow is Saturday and I have a half a
day to mount the rails to the chair. Of course I will have to take it all
apart, wrap all the pieces and ship them home to do the actual glue up
and final assembly. I have so much work left to do that I don’t
expect to be done for at least 2 or 3 months since I have to go back to
work. Vacation is almost over..
Today I glued the stand
offs to the rails, created the dowel ends on all the back slats and
started to refine them. I also got more grinding done to form the second
arm and copied all the templates and jigs so that I will be able to make
another chair after this one is done.
Bill has been such a help
and a great teacher. I have taken my woodworking skills to a whole new
level on this trip and I am so thankful for this chance. This was an
intense week.
Enjoy the following photos.
 
runner out of the clamps
second view
 
gluing on the standoffs
second view
I don’t expect to be
able to post tomorrows photos for a few days. I have to travel home
first. I hope that you enjoyed all of this. I plan to post more as I
finish the work in my shop.
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