BILL KAPPEL
1115 S 100 E, EPHRAIM
UTAH, 84627


435.283.3193
bill@kappelusa.com

The Rocking Chair Guy

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Sam Maloof Collection

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

http://kappelusa.com/

                                                                    

                                 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

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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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Some student rockers

 

 

 

 

 

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npete County Visitors Website.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

© 2008 Bill Kappel ~ www.kappelusa.com