Looking for a stylish and comfortable patio chair project? Anthony and Bob Barker from Wood Pack DIY have created a fantastic guide for building a pair of patio chairs that will elevate your outdoor space. Follow along with this detailed tutorial to create your own durable and attractive patio chairs!
Materials and Tools Needed
- 4×4 kiln-dried lumber
- 2×3 lumber
- 1×4 lumber
- Wood glue (water-resistant)
- Exterior rated screws
- Bead lock system (optional)
- Wood clamps
- Digital angle finder
- Spar urethane finish
- Tack cloth
- Drill
- Miter saw
- Forstner bit
- Router
- Sandpaper
- Wood filler
- Leg levelers
Step 1: Breaking Down the Lumber
To start, Anthony breaks down the 4×4 lumber into smaller pieces needed for the legs of the chairs. He emphasizes the importance of using kiln-dried lumber, having learned the hard way that non-kiln-dried lumber can crack when cut. Using a stop block ensures that all pieces are cut consistently.
Step 2: Shaping the Legs
After cutting the legs, he shapes them by putting a bevel on the edges using an angled blade. This adds a nice contour to the legs. It’s important to save scrap pieces as they might be useful later in the build.
Step 3: Creating Miter Joints
To connect the legs, Anthony uses miter joints for a more polished look. He employs a bead lock system to create strong joints. This involves marking a center line, clamping the jig, and drilling holes that will allow for a snug tenon fit.
Step 4: Gluing and Clamping the Joints
Once the tenons are prepared, Anthony applies glue and uses clamps to secure the joints while they dry. He also makes culls from scrap wood to help apply pressure to the joints during drying.
Step 5: Building the Seat Frame
Next, he cuts down 2×3 and 1×4 lumber for the seat frame. Using pocket holes and exterior screws, he assembles the frame while ensuring everything is square. This step is crucial for a solid foundation.
Step 6: Installing the Slats
With the frame complete, it’s time to install the slats. Anthony uses spacers to ensure equal spacing and secures them with screws from the bottom supports, keeping the screws hidden from view.
Step 7: Making the Seat Back
For the seat back, he again uses pocket hole screws to keep the assembly clean. He angles the top for a comfortable recline and temporarily clamps the pieces in place while securing them.
Step 8: Final Assembly and Supports
After constructing the seat back, Anthony secures it to the frame, ensuring all screws are hidden. He adds additional supports for extra stability.
Step 9: Adding Finishing Touches
To finish, Anthony sands the entire chair to smooth out any rough edges. He applies a light stain and three coats of spar urethane to protect the wood from the elements.
Step 10: Final Inspection
With the chairs complete, Bob Barker gives his approval, noting their comfort and style. Anthony encourages viewers to check out the detailed plans available for those interested in making their own set.
The project is a success, and these patio chairs are sure to enhance any outdoor space. For those interested in building a full patio furniture set, stay tuned for more projects, including a sofa and coffee table!