I have been working on a factory made Henredon furniture bed that had an entire leg break off, and get lost during a move. No one knew what happened to it. The movers asked if I could make a new one from scratch.
This leg was very curvy, and was hollowed out in the middle. It also has a decorative routed front. I know this was going to be a challenge.
After using my Jigsaw and coping saw to cut out the shape of the leg, I used my #5 Craftsman Jack plane to get it to the right thickness. I then scored a line across with my tablesaw to the depth that I needed to hollow it out.
Now the fun begins. I got out my hatchet and started hacking away. I used handplanes number 1, 2,4, 5, 33, Round moulding plane, and a round micro rasp to hollow it out, and smooth edges. I ended up buying a small power plane, and an expensive carving gouge to help with the job. I then used my 2 favorite power sanders to finally get it smoothed out. I also used a benchtop power sander. Whew what a job!
After a couple of blisters, and a few splinters I was finished carving it out.
I started the finishing process, and then matched the color.
Next I attached it to the Bed Footboard.
I think I used about 20 tools to make this leg. This was a fun challenge, and I am glad that it is finished.
Curvy legs are my specialty 😉
Zeke Willard