Evening All,
This is my first attempt at a Maloof style chair and Im off with a bang. I am embaressed to say I worked on this joint for about 3 hours today. I have made all the correct measurements and am using a 3/8″ rabbet bit and a 5/8″ roundover bit but for some reason I cannot get it to work. I have included 3 pictures to help. One of the pictures shows the gap I have between the verticle piece and the horizontal piece. The other two show the sides of the joint which are perfect. For some reason the radius’s just wont match. Anybody have any ideas. I have triple checked everything but still cant get it to fit? ANY advise would be greatly appreciated.
Thanks,
Jeff
Replies
I have no idea!
I do not know what plans, if any, you are using but from the picture it looks like your joint cutting skills are excellent.
I can only wonder from your statement about using a 3/8" rabbet bit and a 5/8" roundover bit.
The radius of 5/8 (0.6250) times two equals 1.250 inches
for a mating surface/tool diameter. Are you using a pattern to guide
the rabbet bit?
Sorry, when it comes to math I'm the dim bulb on the Christmas tree!
Then again, maybe Sam Maloof hand fitted those mating surfaces?
Your radii aren't correct.
If you are using a 3/8 inch diameter rabbeting bit to create the cut out in the seat, the radius of the inside corners is 3/16 inch, one half the bit's diameter. The roundover bit will also need to create a 3/16 inch radius roundover for the two parts to match.
Looking at the photos it looks more like you are using a 3/4 inch diameter straight bit for the seat cut out and for that you will need a 3/8 inch radius roundover bit to create matching curves.
John White, Yestermorrow School
Edited 11/24/2007 1:39 pm ET by JohnWW
Looking at the photos it looks more like you are using a 3/4 inch diameter straight bit for the seat cut out and for that you will need a 3/8 inch radius roundover bit to create matching curves.What I initially came up with looking at the photos. However, I tried fitting a a 3/4 inch brass rod to several of my 3/8 inch roundover bits but the fit was not perfect. Very close, but not the same. What was strange is the roundover bits (3) were all from different manufacturers but the fit to the 3/4 inch brass rod (yes I checked the diameter) were all about the same. Very close but not a perfect fit. Any reason why?
John,
I figured it out. What you actually need is a 3/8" rabbiting bit that MUST HAVE a 1 1/4 diameter. My 3/8" rabbiting bit (whiteside) was actually oversized and measured 1 3/8 in diameter.
When making this joint, you MUST have a 3/8" rabbiting bit with a diameter of 1 1/4" and a 5/8" roundover bit.
I went out and bought the correct rabbiting bit and the joint works perfectly.
Thanks,
Jeff
The cutting edge of the bit isn't an exact 3/8" diameter because the carbide is at an angle to the edge that it is cutting on the stock, which requires the profile of the carbide to be slightly oval, but it will create a true round surface.John White, Yestermorrow School
If you want to save the vertical piece that you've made,
and if you can afford to have the vertical piece move inboard about 1/8 inch,
you might consider saving the vertical piece by judiciously filing it until it exactly fits the horizontal one.
For what it is worth try these.
Thanks for the clarification.
Files will definitely not work.
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