CREATE THE PLYWOOD SIDES
The sides are cut from 48 × 48" pieces of 3/4"-thick plywood. Start by using the porch rocker detail drawing to lay out the rocker sides on 3/4" plywood. Lay out the side pattern on a 48 × 48" piece of plywood. Make marks at 1 1/2" intervals along all sides, then connect the marks to create a layout grid. Use the side pattern as a reference for drawing the side shape onto the plywood. Once the sides are laid out and marked, cut out the rocker sides using a jig saw (photo A). For interior cutouts, drill out the comers with a 3/8" bit, then use a jig saw to connect the holes by cutting along the layout lines. Lay the side on another 48 × 48" piece of plywood, trace the design and proceed to cut out the other side. Use a router with a 1/4" roundover bit or a palm sander to smooth all of the edges, except those edges where the arms will be attached.



CUT THE SLATS, CLEATS AND STRETCHERS
The slats, cleats and stretchers are very simple to make. Start by cutting the back slats (B) to length from 1 × 4 lumber. Lay out a 3"-radius contour on the top ends of the two outside slats using a compass or by simply tracing an appropriately-sized tin can, then cut the curved contours with a jig saw (photo B).Smooth out the jig saw cuts with a belt sander or a drum sander attachment on a drill. Next, cut the seat slats (C) to length from 1 × 4 lumber and the stretchers (D) to length from 1 × 3 lumber. Then cut the seat cleats (F) and (G) to length from 1 × 2 lumber.



MAKE THE ARMS
Making the arms involves cutting tapers and radius corners, and also requires you to cut a groove with a router. Start by cutting two 24"- pieces of 1 × 6 lumber. Lay out the arms on each piece according to the arm detail diagram. Then, clamp the pieces to your workbench and, using a router with a straightedge cutting guide and a 3/4" straight bit, start at one end and cut a 3/8"-deep, 3/4"-wide groove down the center of each arm (photo C). Stop the groove cut 1 1/2" from the front edge of the arm, otherwise the groove will be visible from the front of the rocker. Next, cut out the arms along the layout lines. Cut the curved corners with a jig saw and the tapers using a jig saw or circular saw. With a router and a 1/4" roundover bit, smooth all of the edges on the arms. Sand all of the edges and surfaces before assembly.



ASSEMBLE THE PORCH ROCKER
The assembly is fairly quick and easy. On the inside surfaces of the plywood sides, lay out the locations of all stretchers according to the detail diagram. Drill pilot holes from the inside out, then on the outside surface, counterbore the pilot holes (photo D). Fill the screw holes with wood filler when assembly is complete. Next, lay out the locations for the seat cleats, then glue and screw them in place using #8 × 1 1/4" wood screws. Drive the screws through the cleats into the rocker sides. Attach the stretchers, using glue and screws, in the designated locations on both rocker sides. Start with the four corner stretchers, then the two remaining stretchers. Attach the seat slats to the seat cleats using glue and wood screws, again slightly countersinking the screws so the holes can be filled with wood filler. Complete the assembly process by attaching the back slats to the stretchers and to the rear seat slats using glue and screws (photo E). Use 3/8"-thick pieces of scrap wood for spacers between the slats to keep them properly aligned during the assembly process.

APPLY THE FINISHING TOUCHES
Fill all open screw holes and voids in the plywood using a quality wood filler. Finish-sand the surfaces and edges of the rocker by hand or with a palm sander, generally up to 150-grit. Be sure to use a quality primer and then a quality enamel paint, designed for exterior use and greater durability. Choose a light color to reduce the heat absorption from direct sunlight.