April Wilkerson, presents an easy-to-follow guide on building a modern chunky chair perfect for your patio or indoor space. Below are the materials and tools you’ll need, followed by a detailed step-by-step tutorial.
Materials and Tools
- 4×4 Cedar lumber
- Wood glue (DAP Weldwood Professional Wood Glue)
- Spax Powerlags (5 inches long)
- Spax Deck screws (stainless steel)
- Wood plugs (cut from the same or contrasting material)
- 15-gauge nailer (or 18-gauge if you have it)
- Table saw
- Miter saw
- Jointer and planer
- Drill press
- Combination square
- Clamps
- Mallet
- Bench vice
Step 1: Prepare Your Materials
Start by cutting your 4×4 Cedar down to size using a miter saw.
Step 2: Smooth the Lumber
Use a jointer and planer to smooth out the rough edges of your Cedar. If you don’t have a planer, you can leave the lumber at its original thickness.
Step 3: Cut the Parts
Now that your lumber is prepared, it’s time to cut the parts for the chair. Set your table saw to the appropriate bevel angle for the parts that require it. For the leg parts, ensure that you create a bevel at the base to form a built-in foot.
Step 4: Assemble the Leg and Arm Assembly
Lay out your parts to ensure everything fits correctly. Mark the screw placements and use a drill press to create holes for your screws. This project will utilize butt joints secured with 5-inch long Spax Powerlags.
Step 5: Glue and Clamp
Apply wood glue to the ends of your parts, then clamp them together, ensuring they are properly aligned. Let the glue set before proceeding.
Step 6: Plug the Screw Holes
To hide the screws, use a plug cutter to create wood plugs from the same or a contrasting material. Insert these plugs into the screw holes using wood glue, and then trim any excess material.
Step 7: Build the Seat and Back Assembly
Repeat the process for the seat and back assembly, applying wood glue and using deck screws to secure the parts together. Consider working with gravity by assembling the back stretcher on the ground.
Step 8: Attach the Seat to the Back Assembly
Align the seat back with the legs and secure it using construction screws, hiding the screws where necessary to maintain a clean look.
Step 9: Add Decorative Features
For an extra touch, consider adding an accented X inside the leg assembly using 1×2 material. Paint it black for contrast and secure it with glue and pins.
Step 10: Final Touches
Once everything is assembled, you can sand down any rough edges and apply a finish if desired. This chair not only looks great but is also comfortable and sturdy, perfect for enjoying the outdoors.
You can buy the full plans here.