The Handcrafting of a Rocker Blotter

 

I make every rocker blotter as though I am making it for myself.

Beginnings

 1.  I use quality American Red Oak

 

 

 

 

 

 

The Base

 

2. For the bottoms, 1 x 4’s are glued up face to face.

Standard Sized

 

3.  The length of the arc will cover a personal check in one motion.  This simple jig helps provides a nearly consistent pattern for the next step.

 

 

 

Rough Cuts

 

4. Rockers are rough cut on a band saw.

 

I usually work on 12 to 16 pieces in a group

 

5.  There’s a lot of work to do in smoothing these out.  No two are exactly the same varying in grain and slightly in size and shape.

 

 

 

This is an awesome machine!

 

6.  An oscillating belt sander is used to smooth out the bottoms. This process takes 10 to 15 minutes for each rocker

 

Smooth Operator

 

7.  Each bottom is checked for squareness to insure a smooth rocker motion

 

 

 

Cutting Top Sections

 

8.  Tops are ½ inch oak stock and cut to width, matching the width of the rockers.

 

Matching Top Sections

 

9.  Individual tops are cut to match the length of  each different rockers so that each set of top and rocker bottom are individually matched.

 

 

 

Shaping the Sides of the Top Section

 

10.  Tops are edge shaped using a table mounted router and Roman ogee bit.

 

Preparing for the Knob/Handle

 

11.  Center holes for the handle bolt are drilled

 

 

 

Preparation for Inserting Hardware

12.  Using the top as a template the hole for the insert nut is marked.

 

Drilling the Base in Preparation for Installing the Insert Nut.

 

13.  Holes for insert nuts are drilled. Scrap cutouts are used to stabilize and center the rocker bottom.

 

 

 

Countersinking

 

14.   The top 1/16th of the hole is widened to counter sink the insert nut thus insuring a snug and flat fit for the top section.

 

Insert Nuts

 

15.  Insert nuts are used to anchor the brass knob post.

 

 

 

Installing Insert Nut

 

16.  Insert nuts are screwed into place using an Allen wrench

 

Numbering

 

17.  Paired tops and bottoms are numbered to keep them together through the sanding, staining, and finishing process.

 

 

 

Sanding, Sanding, Sanding

 

18.  Tops and bottoms are hand sanded at 120 grit, inspected for scratches, then sanded again at 150 grit, and re-inspected again.  This is the longest single step sometimes taking 20 minutes per top and bottom set.

 

 

 

Branding

 

19.  The underside of the tops are branded with a simple note of origin.  This is not visible in the assembled finished product. 

 

 

 

Preparing for Finishing

 

20.  Tops and bottoms will be thoroughly cleaned of dust in preparation for staining.  A temporary post is placed in the bottom and top sections to enable handling of the pieces during the finishing process.

 

Staining (coloring)

 

21.  Some blotters are stained with a mixture of Minwax Dark Walnut (2716) and Minwax Provincial (211).  This combo provides a pigment stain which enhances the grain and a dye stain for surface color.   Please see the Custom’s Options page for more color choices. 

 

 

 

Gel Stains are Also Excellent

 

23.  I also like to use Wood Kote’s Jel’d stain, a pigment stain that accentuates the grain and  it is very easy to work with.

 

Some Folks Prefer the Natural Color of Red Oak.

 

24.  Some blotters are left unstained displaying the natural beauty of the red oak.  

 

 

 

Preparing for Finishing

 

25.  All tops and bottoms, both stained and natural, are then brushed with a sealer coat of 50% polyurethane varnish and 50% paint thinner.

 

The “Rocker Blotter Incubator”

 

26.  Drying time is at least 8 hours between sealer coat and each successive top coat.  These rocker blotters dry in a dust free tent.

 

 

 

Removing the “Nibs” After the First Sealer Coat.

 

27.  After the sealer coat all pieces are lightly sanded with 600 grit paper to remove all the “nibs” that always rise after the sealer coat.  This is insure a very smooth final finish. 

 

Finishing up with 3 Coats of Sealer.

 

28.  Then each top and bottom receives 3 top coats of polyurethane varnish.  The thick top coat will protect them from inks and naturally occurring body oils from the hands. They are easily cleaned with a slightly dampened cloth or a liquid polish if you prefer.  Each piece is lightly smoothed with 0000 steel wool between coats.

 

 

 

Installing the Brass Knobs

 

29.  Temporary zinc studs are replaced with brass studs and topped off with a Liberty solid brass knob.  There are various knob choices that you can see on the ordering page.

 

Installing the Blotter Paper

 

30.  The brass knob is loosened, blotter paper is fitted and the knob is re-tightened and you are ready to go.  Each rocker blotter I sell comes with 10 sheets of blotter paper and you can easily order more here or from many places on line.

 

 

 

 

Your New Rocker Blotter Will Last for Many Years!