These nesting chairs were designed by Jay Bates and built by Brett from Brett’s Basement Woodshop. This guide will walk you through the step-by-step process of crafting these chairs, perfect for any outdoor gathering or cozy camping trip.
Materials:
- Exotic hardwoods (Purple Heart, Ash, African Mahogany)
- Wood glue
- Finish (Spar Urethane)
Tools:
- Table saw
- Jigsaw or bandsaw
- Drill or drill press
- Router with a flush trim bit and quarter-inch roundover bit
- Miter saw (optional)
- Thickness planer
- Clamps
- Finish nails
- Plug cutter
Step 1: Gather Your Materials
Start by pulling out your wood. I’m using Ash for the slats and African Mahogany for the legs, along with Purple Heart for the main structure. Make sure your materials are all about one inch thick.
Step 2: Layout and Milling
Since this wood is expensive, lay out your pieces before milling to minimize waste. Use a thickness planer to flatten out the rough lumber. Aim to get both sides flat and let the boards rest to equilibrate moisture.
Step 3: Cut the Legs
Using a bandsaw, begin cutting out the legs, ensuring to stay about an eighth of an inch away from the line. For tight turns, drill relief holes to help maneuver the blade.
Step 4: Routing the Slots
For the captured slat, use an 11/16″ Forstner bit to hug out the material before routing. Use a half-inch spiral down-cut flush trim bit for clean edges.
Step 5: Making the Arms
The arms should be longer than those on my previous cedar chair. Use the existing arms as a template for the new ones.
Step 6: Assembly of the Chair
Assembly is straightforward thanks to the templates. Start with the back support, clamping the lowest slat in place while leaving a quarter-inch overhang on both sides. Then install the top slat, drilling pilot holes to prevent splitting.
Step 7: Adding Finishing Touches
After sanding everything to 180 grit, it’s time to apply the finish. Wiping on Spar Urethane can be tricky, so consider using a sprayer or bristle brush instead to avoid drips.
Conclusion
And there you have it! Your beautiful nesting chairs are ready for use. If you want to build your own, check out the links to the plans and templates here.