The Heirloom Rocking Horse

Step 1: Getting Started
The first step is to make your full-size patterns. There are two ways you can accomplish this. The first is to follow the drawings provided and make full-scale patterns for parts A through H. Begin by drawing 1" grids on pieces of cardboard or artist's board and then duplicate your drawings onto this larger grid. The optional method involves going to a local copy center and enlarging the patterns provided here by using a large format, roll-fed copy machine. These machines typically enlarge up to 400% in a single pass, so you'll have to make multiple passes to get to the desired dimensions.

Once you've drawn (or copied) your patterns, cut them out and trace them onto a 6-foot and 8-foot length of 2" x 12" stock (we used yellow pine). Work around any knots or defects in the wood and for maximum strength, be sure to follow the grain direction indicated by the arrows on the drawings.

Next, cut your stock into manageable sized pieces before attempting to cut out the final shapes with your bandsaw, saber saw or scroll saw. The saddle (G) can be made from your choice of 2" x 12" stock, then shaped....or from 3/4" stock (H - not shown) and then upholstered (see Step 11).

Cut the braces (J) to size and chamfer the edges using your Table Saw, Disc Sander or Jointer.

Step 2: Drill the holes
for the handle, eyes and tail where noted in the drawings. Drill the alignment holes in parts B,C,D,E & F, as shown. Locate these holes very carefully since they will be used to align the various parts of the horse during assembly. Drill the holes for the legs (parts B & C) from the back, being sure not to drill all the way through the stock to their front sides.

Step 3: Sand all contoured parts
using your disc and drum sanders. Tape the two rockers (A) together with double-faced tape and pad sand them together at the same time to be certain their contours are identical. See Fig. 1.

Step 4: Use the Shaper
with a Tongue Cutter to create the 1/4" deep groove in the back of the head (E) that will accept the rug yarn mane. See Fig. 2
 
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