Help making up some massive legs

[humantorch]

Hey all,
So I have a client that is looking for a coffee table with some massive legs. This is normally not my cup 'o tea but I'm very strapped for dollars and this client has a lot of them. (I do much more modern stuff)
That said attached is a picture. I really have no idea how to go about gluing up the pieces so that I don't run into issue with wood movement later on down the road.
Does anyone have any suggestions? They are roughly 14" x 14" x 18" and I'm thinking walnut or oak. I may try and guide the client toward NOT having the "L" in the inside of the legs and having just large rectangular posts instead....Just for ease of build.
My thought was to glue up a bunch of 8/4 stock and then square it all up and hand carve the curves.
Any and all input on this would be greatly appreciated.
Thanks!!!

[attachimg=1]

 

[windmill man]

The four legs put together make a circle with a square hole in the centre, so laminate a blank of the appropriate size  around a square blank put it in a lath and turn it then split into the four quarters.

 

[mouppe]

The four legs put together make a circle with a square hole in the centre, so laminate a blank of the appropriate size  around a square blank put it in a lath and turn it then split into the four quarters.

You'll need a lathe that can turn a 28" diameter spindle if I am reading the OP's measurements correctly- that's massive!

I would glue up three pieces of stock into an L-shape, leaving the missing quarter as the rebate. Then you can carve the outer shape. Wood movement should not be a problem because the glass is floating and the glue joints are all long grain to long grain.

 

[humantorch]

Thanks RL...yeah a 28" lathe isn't happening.
My concern is even getting stock that's thick enough for the 3 pieces. I was thinking I would have to use a bunch of 8/4 and then I would have an eventual issue with face vs edge grain when rounding the outside edges.

 

[Brent Taylor]

You may want to try a stacked build up, I assume that you have a router and can make a circle template.  I would do a full size drawing to refer to also.  I use to work for an Architect and he was always finding new ways to twist my nut, but I always figured out a way.  If I can think of anything easier I will post. Good luck. 

 

[humantorch]

Brent,
I do have a router and a jig but I'm not exactly clear what you mean by a stacked build up? Like alternating stacks (log cabin style?) of circles cut out of glued up panels to create the curve? And then do as first poster suggested and quarter the entire stack?
Would the perpendicular long grain glue up not compromise the structure?

 

[flair woodworks]

Very interesting problem you face.  I don't really have any new suggestions, except for "accidentally" making the legs 14mm x 14mm x 18mm instead

 

[tiralie]

The four legs put together make a circle with a square hole in the centre, so laminate a blank of the appropriate size  around a square blank put it in a lath and turn it then split into the four quarters.

Agreed. A good lathe can handle that size blank.
Probably not in your average turners skill set though. Call Oneway lathes and ask them if anyone in your area bought a lathe from them capable of turning that size 28" blank. Then call them and ask if the could turn it for you. Can't hurt.
Some Oneway lathes can take a 48" blank.
Tim

 

[Brent Taylor]

What I was  thinking would be making rings of what ever species you have, joining them with dowels, diminos, biscuits,  pocket screws, whatever you have that will hold the ring together as the glue dries. Then route the outside profile for that elevation of the leg. Then the next level and so on, until you reach the top of the leg blank. I am sure you will have to blend it with a sander or two. It would be similar to making a turning blank of that size. Glue and dowels or screw the levels to one another. Look at some of the turning video's. The only difference is that you are routing the profile instead of turning them. Hope this  is  a little clear.   

 

[Kev]

Does this need to be a solid structure? Really curious regarding the expectation for grain.

Would a series of curved edge wedges with a shaped box and a top plate work? You could alternate the wedges with varied grain or light and dark wood for an interesting effect!

 

[tiki man]

Looks like something that I would try to do with a vacuum press some forms wiggle material and veneers.
Make each leg out of 3 pieces with three vertical forms some wiggle material and veneer and attach those together to make your leg. Once you have made one you can make as many as you want.

Should be work pretty good and you won't have to cut down half a forrest to make four legs...

 

[Brent Taylor]

I should have also stated that the type of router base I had used was a Makita tilt base, the newer 1 1/4 hp model is better than the older one I used, I think Bosch has one also. I also had made a jig that used a lazy susan roller attached to a plywood base that I attached to my table and radial arm saw bases to cut circular profiles, I hadn't thought of that jig for years, used it back in the 80's, when everyone had a radial arm saw (thanks  Norm) .

 

[WarnerConstCo.]

I could turn that, don't have a one way though.

 

[tiralie]

I could turn that, don't have a one way though.

I figured you could.
I should have just suggested you to [member=25598]humantorch[/member].
Tim

 

[Hud]

Have you considered stack lamination, you can rough cut to size each level and carve to finished shape,  The lamination glue lines become you shape defining points.  You will need to make a drawing and make lines at each glue interface (thickness or the boards) to determine the exact shape at the top of each lamination piece so you have a known shape at each glue interface.  This techniques has been used for furniture (Wendell Castle) and by wood pattern makers for large accurately dimensioned objects.

 

[humantorch]

Hud,
That's where I was at with my thinking....until the client decided they wanted to look "salvaged" (and then sent me a pic of a Restoration Hardware piece)....So now I'm back to square 1 and thinking I have to glue up 3 large pieces roughly 7 x 7 x 18 and carve them with a carbide disc on my angle grinder.....(I've already tacked on the appropriate + 15% for the pain in a$$ client factor)

 

[tiralie]

When you first posted I thought this was a derivation on Restoration Hardware reclaimed stuff.
I would still have them turned and then "distress" them. It's pretty easy to get a nice piece of wood to look like crap er, reclaimed...I know I've had lots of practice.
Tim