This project is by Johnny Brooke from Crafted Workshop, showcasing a modern Adirondack chair that blends comfort with a sleek, contemporary design. The chair is made primarily from thermally modified ash, a durable wood that resists rot and pests, making it ideal for outdoor use. If you’re looking for a stylish and sturdy addition to your patio, this project is worth exploring.
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Preparing the Wood
The first step in this build is preparing the wood by cutting the boards to rough lengths using a miter saw and bandsaw. This makes handling easier before moving on to more precise shaping. Thermally modified ash is known for its strength, but it can be brittle, so careful cutting is essential to avoid splitting.
Once the rough cuts are complete, the edges are refined, ensuring each piece is square and properly sized for assembly. Proper preparation at this stage helps the final structure come together smoothly.
Creating the Metal Framework
To enhance stability, the chair design includes a metal framework for support, especially in the arms and back. Initially, aluminum was considered, but challenges with brazing led to a switch to copper. Copper is not only easier to work with but also provides a durable and cost-effective alternative.
The copper tubing is cut to size using a pipe cutter, ensuring precise, clean edges. Before soldering, the surfaces are cleaned with a wire brush, and flux is applied to improve adhesion. The soldering process involves heating the joints until the solder flows evenly, creating strong, secure connections.
Building the Wooden Structure
Once the metal framework is complete, the focus shifts back to the wooden components. The chair’s arms and legs are cut to size, and the initial joinery is established using pocket holes. However, thermally modified wood can be brittle, leading to some splitting during assembly.
To prevent further cracking, thin CA glue is applied to any affected areas, and clamps are used to stabilize the pieces while pre-drilling screw holes. This extra step ensures the structural integrity of the chair without compromising its design.
Assembling the Chair
The back legs are cut at a 20-degree angle to provide the proper recline and support. After marking screw hole locations on the front leg, the back leg is carefully clamped and secured, ensuring a solid and stable connection.
The back panel consists of four boards, reinforced with cross supports for extra strength. Once attached to the back legs, the seat slats are installed, starting with the front piece and working backward. Consistent spacing is maintained to enhance comfort and aesthetics.
Finishing Touches
Before finishing, the copper base is removed for cleaning. Any excess solder is filed down, and a self-etching primer is applied before painting the copper frame in flat black for a modern look.
For the wooden components, all visible screw holes are plugged using a plug cutter, ensuring a seamless appearance. The plugs are made from the same thermally modified ash to blend in naturally. After a final sanding, the copper base is reattached, completing the build.
The Finished Chair
This modern Adirondack chair is both visually striking and highly functional. The combination of thermally modified ash and copper results in a unique, durable outdoor seating option that stands out in any space.
For those interested in making this chair, detailed plans are available, providing a step-by-step guide to replicating the project.