This project was built and designed by Anthony from Wood Pack DIY, with helpful on-site supervision from his loyal assistant, Bob Barker. These outdoor chairs are a perfect blend of comfort, durability, and clean design—ideal for any patio or backyard space.
With a mix of thoughtful joinery and straightforward construction, Anthony walks through the entire process of building two matching chairs. The result is a professional-looking set that any DIYer can tackle over a weekend.
Watch the full video and subscribe to Anthony’s channel:
Selecting Materials That Last
The build begins with smart material choices. Anthony selects kiln-dried lumber for its stability and resistance to cracking, especially in outdoor environments. This step helps ensure the finished chairs will stay strong and attractive over time.
To maintain visual consistency, he breaks down a 4×4 into smaller parts for the legs and other components. A stop block setup is used to guarantee identical cuts, keeping all the pieces uniform in size and appearance.
Shaping and Detailing the Chair Legs
After rough cutting the lumber, the chair legs are shaped down to a slimmer profile. This is done by adjusting the table saw blade height and running the material through in a controlled manner, removing just enough material to lighten the look without sacrificing strength.
Beveled edges are added to the legs next, giving them a clean, finished appearance. These small details elevate the design and make the chairs feel more refined.
Creating Clean, Strong Joints
Rather than using standard butt joints, Anthony opts for mitered corners on the leg assemblies. This not only looks better, but also reduces the chance of separation over time when paired with strong reinforcement.
To strengthen the miter joints, a bead lock system is used. Once the holes are drilled, the parts are clamped and prepped for glue-up, ensuring a snug, precise fit. Bob Barker keeps a close eye on things from the sidelines, no doubt inspecting for proper alignment.
Constructing the Seat Frame
With the legs complete, attention turns to building the seat structure. Anthony uses a combination of 2x3s for the main frame and 1×4 boards for the seat slats.
Pocket hole screws are used throughout the assembly to hide fasteners from view. Water-resistant glue and exterior-grade screws help protect the build from the elements, extending the life of the chairs.
Installing the Seat and Back Slats
Next, Anthony cuts and installs the seat slats, spacing them evenly using shop-made spacers. The slats are screwed in from underneath to maintain a clean, hardware-free look on the surface.
The backrest is built using a similar technique. With attention to layout and spacing, the slats are secured in place using pocket screws, and the overall shape of the chair starts to take form.
Sanding, Shaping, and Structural Support
Before finishing, Anthony rounds over all exposed edges with a router and gives everything a thorough sanding. This step is especially important for outdoor furniture, where smooth corners enhance comfort and safety.
To improve overall rigidity, extra supports are added in key areas—particularly between the rear legs and the seat back. These braces help reduce flex and make the chairs feel solid when in use.
Staining and Finishing for the Outdoors
With the build complete, it’s time to add color and protection. Anthony applies a light wood stain to bring out the grain and tie the chairs into the rest of his patio setup.
After staining, he applies a spar urethane topcoat for long-lasting outdoor durability. This protective finish guards against moisture, UV exposure, and daily wear from outdoor use.
A Weekend Project with Professional Results
These patio chairs look great, feel solid, and were built using tools and techniques that many DIYers already have on hand. The design is adaptable too—you can scale it up, change the slat spacing, or modify the dimensions to suit your own outdoor space.
With Bob Barker monitoring quality control every step of the way, Anthony wraps up another successful outdoor furniture project. This build adds not only functionality, but also style to any backyard or patio area.
Please support Anthony (and Bob Barker) by visiting their website (he sells awesome plans): https://www.woodpackdiy.com/.