Sander for Maloof-Style Rocker

[Steve F]

In preparing for a possible Maloof-style rocker build someday, I realize that I will need a small sander to shape the seat and joints (already have the angle grinder).  Just wondering what you recommend.  I have a Festool Rotex 150" and ETS 150, but both are too big for that.  My choices appear to be:

1.  RO 90
2.  RO 125
3.  RAS 115
4.  Ceros 5"
5.  Something else

Pneumatic would be nice, but I don't think my compressor is big enough for one.

Thanks in advance,

Steve

 

[PaulMarcel]

A friend of mine has made 5 Maloof-style dining chairs and 3 benches in the style.  No rocker, but what you are wanting to do overlaps.

He did the first seat with a grinder.  I sent him to Charles Neil's "Scoopin' a Seat" video (below) and, in his words, he could do all 4 remaining seats in the time of scooping one by grinder and they were more consistent.  Give it a look; once you understand the method, it goes quickly.

My friend borrowed my RAS-115 to smooth the sides after scooping then used my RO-90 with interface pad to complete it.  Don't recall if he borrowed mine or used his own; he bought one after borrowing it once.

Those were the only two sanders he use; arguably the RAS is more a shaping tool in this case.  You'll find plenty of uses for the RAS beyond this project; it's a gem in the rough.

The RO-90 is really useful; it'll complement your 150 sanders.

 

[Steve F]

Thanks Paul.  I was hoping to avoid buying 2 sanders.  The only difference I see is the faster speed, but can you really use the RAS at full speed with low grits? Is the RAS 115 that much quicker?

Thanks

 

[PaulMarcel]

If you already have the grinder and shaping disc, you could use that to go from scooped seat (à la Charles Neil) to shaped and ready for sanding.  I think you'll still want the RO-90 + interface pad for the rest of the work; as you pointed out the 150 is too large to really finesse the edges.  The RO-90 in disc mode is pretty agressive if you have agressive paper.  Something like P40 or P50 on it (with or without the interface pad depending on what you are shaping) will take care of a lot of stock quickly.  It would save the RAS purchase.  I use the RAS at full speed with P36 and P50 for shaping.

 

[Steve F]

I use the RAS at full speed with P36 and P50 for shaping.

Do you mean instead of a grinder or between the grinder and the RO90?  I have also been doing some live edge stuff and would love something nimbler than the RO 150 to help shape the live edges.

Steve 

 

[PaulMarcel]

My friend never used the grinder when he switched to scooping seats with the dado method; from there, RAS was enough.  A RAS would be slow IMHO as a replacement for the grinder if you are doing the scooping just with a grinder.

So he did it as: scoop with dado, RAS to get to close-to-final shape, RO-90 to fine tune the shape and finish sand the non-flat surfaces.

If you are doing live edge stuff with the RO-150, you will definitely be happy with the RAS-115.  I have the RO-150 and RAS-115; I'd use the RAS for live edge work, definitely.

But again, if you only want to buy one now, the RO-90 would be very useful for this and live edge work while using your grinder for the post dado work.

 

[StevenO]

I've made such a Maloof style rocker, will make more of them.  Without doubt, the most rewarding project ever. Glad you're attempting it -- take your time and enjoy the process. Not an easy project, requiring both precision woodworking and creative artistry.  I use both the RO90 and the ETS 115, as well a grinder and several rasps and files. The project involves tons of hand work which is immensely enjoyable and rewarding.  The RO 90 is great-- very vesatile on this and other projects. The ETS 115 is worthwhile but not as essential as the RO90. 
I researched plans thoroughly and concluded that Scott Morrison (a Montana woodworking who specializes in Maloof style furniture- http://www.finewoodworker.com/  )-- has the closest to true Maloof. His plans and work is not "paint by the numbers" but involves your own skill and artistry. His DVD are detailed and clear--first rate.  Also, when I had questions, I called and emailed him and always got a fast and accurate reply. His work is genuine artistry and he's great.  Unparalled quality.
Regards,
SteveO

 

[jacko9]

I went to a Sam Maloof weekend workshop and Sam used an angle grinder to cut the curves on the chairs.  Sam was kind of a no frills guy who would use his Porter Cable Router switch it off and throw it on his bench still spinning.  He didn't waste time and used the most simple tools available but, he had great skill using those tools.  He used a microplane to smooth the angle grinder cuts and then sand paper. I still have several pages of notes from that workshop that I need to locate.

Jack

 

[Steve F]

StevenO - Thanks for the encouragement and advice.  I have Scott Morrisson's DVD and plans.  I also have Hal Taylor's.  Trying to find the one that is the most idiot-proof.  The RAS 115 is definitely appealing, but I don't think it will replace a grinder and am pretty sure the RO 90 is something I would use a lot.  Except for my TS55 and sanders, I am primarily a hand woodworker.  To make the build possible, however, I am going to use a router for the joints and power grinder and sanders for the shaping.  But, I'm still trying to pull this off without a tablesaw or bandsaw. 
Have a couple of projects ahead of this one, but I need to work on my turning saw skills a bit first anyway.  Hoping to get the wood later in the spring.

Jack - Thanks.  Watching Sam Maloof work must have been an amazing experience.  How cool.  How long ago?

Steve

 

[jacko9]

StevenO - Thanks for the encouragement and advice.  I have Scott Morrisson's DVD and plans.  I also have Hal Taylor's.  Trying to find the one that is the most idiot-proof.  The RAS 115 is definitely appealing, but I don't think it will replace a grinder and am pretty sure the RO 90 is something I would use a lot.  Except for my TS55 and sanders, I am primarily a hand woodworker.  To make the build possible, however, I am going to use a router for the joints and power grinder and sanders for the shaping.  But, I'm still trying to pull this off without a tablesaw or bandsaw. 
Have a couple of projects ahead of this one, but I need to work on my turning saw skills a bit first anyway.  Hoping to get the wood later in the spring.

Jack - Thanks.  Watching Sam Maloof work must have been an amazing experience.  How cool.  How long ago?

Steve

I think it was back in the 80's and I recall Sam telling us that the Social Security people contacted him about why he didn't file to collect since he was over 70 years old at that time.  He told them that he didn't collect because he still worked full time.  Sam was a very friendly guy that gave us his telephone number to call him if we had any additional questions.  I started making one of his round tables the following week and called him to ask about the finish process, he chatted like we were old friends.

Jack