Classic Pony Rocker Plan

Note: if you intend to build this project for use by children, please make sure you follow current governmental safety guidelines for the country, state or jurisdiction in which you live. For the USA, current guidelines can be found at the Consumer Product Safety Commission website: http://www.cpsc.gov/ While efforts are made to design this plan to safety guidelines, no guarantee is made that this plan is current with the particular regulations or guidelines of your governmental jurisdiction.

I am an experienced, fairly skilled woodworker. These plans indicate that the only power tools the author used were a saber saw and miter saw. Although possible, I find it highly unlikely. I used hardwoods which automatically increases the difficulty level, but to cut 2x stock 1 1/2" thick actual measurment with a saber saw is nearly impossible to get a square cut. I have a very expensive top of the line saber saw, and started with that. I only cut about 6" to realize as was my experience that I was not getting a square cut. I immediately switched to a band saw for nearly all my cuts. It is faster, more accurate, and you will get a square cut. Also, a router with a round over bit is a necessity for this project. The author suggests using a utility knife and rasp for rounding edges. I would have been rounding edges for months using that method. Also, I suggest you own a belt sander, and random orbit sander if you plan to do this project, and that your woodworking skills should be above average moderate skill level. By all means, the rockers need to be made from 1 1/2" thick stock, NOT 3/4" as in the plans too weak, even for hardwood and do NOT cut slots in the rocker for the "leg support". That creates a natural weakness at that point and I can almost promise you will have a broken rocker if you cut into it. I used oak for my rockers, and laminated/glued two 3/4 inch pieces together to get 1/1/2" thickness. This made it stronger as the grains run differently in each of the 3/4 boards I glued. I made the mistake of cutting into the rocker for the leg support. Just before assembly, I accidentally knocked one of the rockers on the floor. Oak or no oak, the fall snapped the end off right where I notched into it. Instead screw and glue the leg support boards on top of the rocker.

Love this horse. My father had built them for my two brothers and sisters first born. Now that my father is no longer with us and I have had my first child of my own I had to build one in his honor for my son. Easy to follow plans, just take your time. P.S. a belt sander is a must!

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I enjoyed building this rocking horse. The plans were understandable and to scale. I was disappointed that the plans were on both sides of a single paper however. I made working copies so I could view both sides at once during construction. I liked some of Bill Averbeck's ideas like using oak for the body & rockers, mahogany for the saddle and walnut for the legs. Bill also suggested the use of hardboard patterns which really helped. I strayed from the plans in the following areas: I glued 3/4" material together to make my 1 1/2" body & legs. I made the head and body from one piece. Also I used 3/4" walnut button plugs for the eyes and inserted walnut dowel slices for the nose. I cut a slot for the mouth. For the ears I drilled holes into the head and glued in my ears to achieve a round form. Then I drove short dowels into the center of the ear to add strength. I reduced the hole for the tail to 3/4". I chose to use "Kreg" screws instead of conventional flat head screws which worked for me, although it did reduce the thickness of the hole plugs. I finished "Rocky" with 4 coats of wipe-on MinWax satin polyurethane. I would recommend and purchase another U-Bild plan, but wouldn't hesitate to customize the directions to personal taste or resources. I branded the stirrups and also used a sharpie laundry marker to mark the date under the center rocker support. After I knew the marker was dry, I simply sealed it with the polyurethane. I think one must keep the child's safety in mind all throughout the process. Merry Christmas!

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