Maloof Lounge Chair, deconstructing design and building one

[Bmac]

The objective;

That's all I have to go off, no plans or dimensions, so I'm going to try a deconstruct the design, develop the joinery and figure out the dimensions. Input is welcome! I'm not trying to make an exact duplicate, but I want to develop something very similar. So here are my initial ideas based off the many Maloof chairs I've made.

***Joinery- starting with the front leg, he has the classic Maloof joint at the seat leg interface. I'm sure he used a 1/2" dowel for the arm to leg joint. All of these are very standard in his chairs. Moving to the second joint on the arm, I'm sure the joint is a butt joint with screw reinforcement, again standard design for him. All of these I'm very familiar with. 

The leg to the backrest is likely a dowel supported joint, This is what he uses for his feet on his tables and music stand. Here is where I'll deviate slightly, I'll switch to stacked dominos for this joint. Again I'm familiar with this change as I've done it before with the tables and music stands I've made.

Now to the seat frame. I've not done a Maloof chair  build with a frame before, all the ones I've done have been solid sculpted seats. What I've seen him do on other chairs is a bridle joint for the front joint in the seat frame. In studying this photo and increasing the size it does not look like he used a bridle joint here, It's likely a dowel supported joint.  I think switching to stacked dominos would work just fine here and simplify the construction. The back seat frame support will receive the same domino supported joint, looks like he used a dowel joint here. 

Finally on the the backrest. I'm thinking he has 3 cross pieces, one at the bottom, one in the middle and then the headrest. I can see he used screws for the headrest, but I do not see signs of screws for the other support pieces. I'm assuming those were dowel supported. So I'll try to stay faithful and just switch out the dowels for dominos and use screws for the headrest.

***Dimensions- I have some plans of other lounge chair designs and I have some industry averages. I think I can get in the ball park here. Angle of seat in relation to the floor, angle of seat to backrest, and height of seat in the front are some critical dimensions. Interestingly if you make all the legs on the upper end of the standards length wise, you can always shorten them. Shortening certain legs will also affect some of the angles. The only angle/dimension that is set is the seat to backrest angle, all the others can be manipulated. 

***Patterns, this is were I hope to start this week. The front leg design is pretty identical to the rocker, just needs to be longer. Arm rest will likely be very similar to the rocker also. To me the main patterns that are different and I need to develop are the backrest supports and the side seat frame/back leg. 

***Upholstery- I have yet to talk to my guy, but I think there are 3 "panels" of upholstery in this piece, the seat and 2 in the backrest. I'm assuming my supports will frame out those panels and also assuming Wood strips and possibly corner supports will be needed for the upholstery. I'll confirm or correct my assumptions after I speak with the upholstery guy.

So I'm totally open to suggestions and ideas. Maybe you think I'm on the right track or maybe you think I'm totally off base, but I'd love to hear your thoughts. This is very much a stretch for me but I'm excited to branch out with a new challenge. 

Thanks for looking!

 

 

[Chestnut]

Here is another view.

from https://www.finewoodworking.com/2009/06/12/new-exhibit-features-never-seen-before-works-by-sam-maloof

It indicates that the chair was made specifically for an exhibit so there may need to be some adjustments made. The only reason i say that is, even with my youthful spry abilities, that chair looks difficult to extricate myself from. My guess is the top of the upholstery is 16" from the ground with the wood frame at 15" but you indicate you have a good idea for that.

The only other thing that I see is if it's a chair with out an ottoman the seat depth looks like it'd cause a persons legs to rest against the front frame of the chair and could cause circulation problems to the feet. I don't have a ton of experience with these chairs so maybe it's ok.

[Mick S]

I'm really looking forward to how you approach this project!

[RichardA]

That chair looks so........ perfectly sleep inducing.

[Chet]

54 minutes ago, RichardA said:

That chair looks so........ perfectly sleep inducing.

Ditto!

[Ronn W]

 I will enjoy following your build.  Just looking at the picture, I liek the angle of the seat to the backrest but it seems that the body position is a lttle too reclined.  Maybe just a bit more upright would work - easier to get into and out of?????

[RichardA]

2 minutes ago, Ronn W said:

 I will enjoy following your build.  Just looking at the picture, I liek the angle of the seat to the backrest but it seems that the body position is a lttle too reclined.  Maybe just a bit more upright would work - easier to get into and out of?????

Why would you want to get out of that chair.  Someone might beat you back to it?  Jeez!

[Bmac]

All good points @Chestnut, these are things I need to tweak. And yes @RichardA It does look sleep inducing. 

Nut that front pic of the chair is great, it helps a ton. Your computer search ability surpasses mine. Was that the only pic you could find? I'd love a shot of it from the back.

So from the new angle I have a few observations. I agree with @Ronn W, it looks like it's reclined a little too much, I'm going to try a lessen that. It also looks like the width of the seat narrows toward the back rest. This was something I was wondering about and this shot confirms that. Saves me some tweaking there. I also don't like the wide arms. I like the way they sweep but I'm going to make them more narrow. I've already done this to the arms on the rocker.

This chair is listed on the Maloof website, so I think this was one of his last designed chair;

http://sammaloofwoodworker.com/seatinglounge.html

Thanks for the input so far guys!

[JohnG]

If you want to make an exact replica, you could buy it for a cool $18,500 and take all the measurements you want!

https://connect.gallerique.com/furniture/seating/upholstered-occasional-chair.html

[Chestnut]

24 minutes ago, Bmac said:

All good points @Chestnut, these are things I need to tweak. And yes @RichardA It does look sleep inducing. 

Nut that front pic of the chair is great, it helps a ton. Your computer search ability surpasses mine. Was that the only pic you could find? I'd love a shot of it from the back.

So from the new angle I have a few observations. I agree with @Ronn W, it looks like it's reclined a little too much, I'm going to try a lessen that. It also looks like the width of the seat narrows toward the back rest. This was something I was wondering about and this shot confirms that. Saves me some tweaking there. I also don't like the wide arms. I like the way they sweep but I'm going to make them more narrow. I've already done this to the arms on the rocker.

This chair is listed on the Maloof website, so I think this was one of his last designed chair;

http://sammaloofwoodworker.com/seatinglounge.html

Thanks for the input so far guys!

Unfortunately I tried to find a back picture as well but was unable. This (http://www.riversideartmuseum.org/collections/) is the art gallery it was made for. I wonder if they have any other pictures they would share with you. Too bad it's in LA, i have little desire to go there.

Found Another not very different angle. To me it doesn't look like it tapers towards the back. If you look the back rest comes strait off the rear legs but the front legs are outside the main frame. I think it just appears to be tapered because of that.

26 minutes ago, RichardA said:

Why would you want to get out of that chair.  Someone might beat you back to it?  Jeez!

Just need to get one of these.

[Bmac]

37 minutes ago, Chestnut said:

Unfortunately I tried to find a back picture as well but was unable. This (http://www.riversideartmuseum.org/collections/) is the art gallery it was made for. I wonder if they have any other pictures they would share with you. Too bad it's in LA, i have little desire to go there.

Found Another not very different angle. To me it doesn't look like it tapers towards the back. If you look the back rest comes strait off the rear legs but the front legs are outside the main frame. I think it just appears to be tapered because of that.

 

I think you are right Nut, I think it's the position of the back support over the leg that gives it the tapered look. In the pic that @JohnGsent it does not look tapered. The first pic you sent me I think the angle it was taken at gives the seat a more tapered look. The nice thing about no taper is I should have parallel inside surfaces of the back supports, definitely helps with construction.

These extra pics are so helpful, thanks guys!!! Sure beats dropping $18,500!

I tried also to go on the art gallery but couldn't find any back photos there. By the way, I also agree with you Nut about not wanting to visit LA either. 

 

 

[pkinneb]

FWIW that back is definitely two pieces. It would be nearly impossible to get that affect with a sewn seam and the tell tale is the corers go up on the top and down on the bottom, stitching would not allow that.

[Chestnut]

28 minutes ago, Bmac said:

I tried also to go on the art gallery but couldn't find any back photos there. By the way, I also agree with you Nut about not wanting to visit LA either. 

I was thinking maybe shoot them a phone call or email and see if they have some for internal purposes. I'd just say I was an art student studying Maloof's later work.

[JohnG]

Luckily it’s in Riverside, not LA  Fly into the Ontario CA airport and you’ll be close and not have to step foot in LA.

The guy that helped me make the ukulele lives close to that museum. I’ll check to see if he has been there and if he recalls Maloof chairs there. 

[Chestnut]

9 minutes ago, JohnG said:

Luckily it’s in Riverside, not LA  Fly into the Ontario CA airport and you’ll be close and not have to step foot in LA.

The guy that helped me make the ukulele lives close to that museum. I’ll check to see if he has been there and if he recalls Maloof chairs there. 

Want to be pedantic fine I have no interest in visiting the Los Angeles-Long Beach CSA ....

Nothing wrong with it, personally my tastes are more for northern CA coastline with the redwood forests. That area is like being on another planet.

[RichardA]

2 hours ago, Chestnut said:

Want to be pedantic fine I have no interest in visiting the Los Angeles-Long Beach CSA ....

Nothing wrong with it, personally my tastes are more for northern CA coastline with the redwood forests. That area is like being on a "real" planet.

Fixed it.

[Coop]

I’m sure, after consulting with your upholstery guy, he can iron out the cushion question with you. With your experience on the shaping and joinery of Maloof’s chairs, there’s probably no better suggestions than the ones you posted. I, like others, question the functionality of the pictured design, other than a place to relax for a long period of time. I.e., getting in and out of it, just too relaxing if that can be a problem. And that’s the problem I had with building Adirondack chairs. I played with different angles until I found one that was not only comfortable but also one that made it easy for an old man to get out of to retrieve a cold beer. My suggestion, and it’s like a student teaching the professor, is to build a prototype from ply and clamps/screws to get your seat back and back legs to floor angles. But I bet you’re already one step ahead of me on that.

You’ve raised the bar if that’s possible, on this one bud. Certainly looking forward to this build. 

[Bmac]

Spoke with the upholstery guy and meeting him this week. That will be a big step and the additional photos you guys found are a huge help. That along with the knowing my joinery it's all about the dimensions now and finding out how to make it comfortable. @JohnG was a huge help finding it for sale, not that I plan to buy it, but the sale page has some general dimensions, over all hieght, width and depth. It's listed as 40 H x 28.5 W x 35.5 D, that gives me a rough idea of the footprint. 

So I plan now to make a simple style lounge chair to start and get a feel for what angles are comfortable. Found a simple design the I can make quickly and play with to help develop my patterns. 

https://www.shaunboydmadethis.com/glenn-lounge-chair

This design is straight forward and the way it's constructed, two sides and a one piece seat, I think I can really play with seat height and pitch of the seat. Sort of like a plywood mock up but still a usable chair when finished. Also it will be a surprise moving gift for my son and his girlfriend when I'm done!

[Chestnut]

That'd be a cool patio chair. It's too heavy handed and bulky though. The arms should be thinner as well as the seat sides. It is a good design that could be made quickly and easily though.

[Chestnut]

Found some interesting information that you might be interested in @Bmac.

https://gallery.collectorsystems.com/MaloofOnlineGallery/2191
https://gallery.collectorsystems.com/MaloofOnlineGallery/2354

It's possible that the chair you are interested in has dimensioned drawings of the exact chair you are interested in. They appear to have a lot of information on that site. It may be worth reaching out to them as well if you are interested.

[Bmac]

1 hour ago, Chestnut said:

Found some interesting information that you might be interested in @Bmac.

https://gallery.collectorsystems.com/MaloofOnlineGallery/2191
https://gallery.collectorsystems.com/MaloofOnlineGallery/2354

It's possible that the chair you are interested in has dimensioned drawings of the exact chair you are interested in. They appear to have a lot of information on that site. It may be worth reaching out to them as well if you are interested.

Awesome sites, thank you. I will definitely look into this!

[Bmac]

OK, things are starting to move. Spent the weekend developing plans between football games. Used full sized graph paper and did it the old fashion way, which helped so I could see the dimensions better. 

Here's the full sized drawing of the seat/leg area and part of the backrest;

The angles I developed are less harsh than the original piece. I did a 5 degree drop from the front of the seat to the back of the seat. Used a 110 degree backrest to seat angle, this gives a total of about 115 degrees of reclining. 

Because the drop was less in the seat, the curve in the back leg had to be more severe and slightly longer than Maloof's chair was. Because of this I dropped the seat height in the front to 16.5" without cushions. Hoping it will end up around 17.5 after cushions. Seat depth is 22". Here's a better pic of the more extreme curve in the back leg;

Fortunately I had the perfect board for these legs, glad I decided to mill this log 2 years ago;

The critical part of this seat is the side seat rail/back leg piece. All the key joints all are in this piece; the front cross support, the leg jt, the backrest joint, and the back cross support. These all need to match each other and the challenge lies here in this build. I'll start with the backrest support, it needs to be square and located identically in each side piece;

Next is the front leg joint. I need parallel top and bottom edges for joinery and a large enough flat area for my router to rest on for the joint;

I'm thinking I need to develop a jig for the tablesaw that utilizes the location of the backrest joint and develops a flat cut for the top side of the board in the leg joint area. Then if I get that section flat I could use the tablesaw fence to cut the opposite side. I've left extra material in this area for this operation and I'll likely leave it a little thicker here for the joinery, then sculpt in the final contours.

 

[Coop]

A lot of thought have gone into getting to the sketch. Looking good! 

[Bmac]

Made some progress, but not a big update.

So as I mentioned before the side leg houses almost all the joinery, and I need to develop legs that match each other and has certain correct relationships. In the front of the leg we need to do our front leg joint, a Maloof joint. I'll need flat areas to run the router and those flat areas need to match leg to leg and the top part of the leg needs to be parallel to the bottom of the leg. Also the angle of the flat surface on the stem for the backrest support needs to have the correct relationship to the front area. Finally, the length of the legs need to match.

So to accomplish this I started with the backrest stem. I clapped the legs together and using a hand plane I worked the joint surface of the stem flat, at a right angle to the exterior face of the leg, and worked it so both stems matched perfectly (which was easy since they were clamped together). Then, while the legs were still clamped together I went to the bandsaw and cut my top line in the front of the side leg and cut the front length for the leg. Then hand planed again these two surfaces until they were flat, at a right angle to the exterior face and so that both legs matched. So in the pic below you can see uniform stem joint areas and the front part of the side leg has matching flat surfaces on the top part of the leg;

Last thing I needed to do was cut the underside of the front part to make that surface parallel to the top. Did that on the tablesaw, no problems.

On to the joint for the backrest support, used stacked dominos here, piece of cake;

And finally for this post I cut my slot for the Maloof joint that connects the front leg to the seat frame. Ready for the router plane;

So those slots were cut into the outer side of the leg/seat side piece. Things are bulky now, and that's on purpose. I need flat surfaces to run my router on. Once I rout out the Maloof joint I'll scribe some lines and go to the bandsaw to cut away some of the excess off the top and bottom of the side leg complex. I'll likely cut into this front leg joint. 

So far so good. I hope to get the frame of this chair put together by the end of this weekend.

[drzaius]

You're making good progress, B. I'd still be looking at pictures.