Looking for a comfortable and stylish Adirondack chair project? This modern Adirondack chair was designed and built by Johnny Brooke of Crafted Workshop, and it’s a fantastic addition to any outdoor space.
Materials
- Thermally modified ash wood
- 3/4” copper pipe
- Copper elbows and end caps
- Wood glue
- 2.5” screws
- Pocket hole screws
- Solder and flux
- Self-etching primer and flat black paint
Tools
- Miter saw
- Band saw
- Jointer
- Planer
- Crosscut table
- Screwdriver
- Drill
- Sanding tools
Step 1: Prepare the Wood
Start by breaking down the thermally modified ash boards into rough lengths using a miter saw and band saw. Joint one face and one edge to ensure they are straight and flat. After jointing, run the boards through the planer to achieve a final thickness of ¾ inch.
Step 2: Create the Metal Framework
Initially, I tried using aluminum for the framework but encountered issues with brazing. Instead, I switched to copper, which is easier to work with. Cut the copper tubing to length using a pipe cutter for precise cuts. Clean the ends with a wire brush and apply flux before soldering the joints.
Step 3: Assemble the Wooden Parts
Once the metal framework is prepared, move on to the wooden parts. Rip the arms and legs to their final width at the table saw and cut them to length. For the joinery, I initially used pocket holes but found that dowel joinery would have been a better choice due to the brittleness of the thermally modified wood.
Step 4: Attach the Legs and Arms
Attach the back legs to the front legs using 2.5” screws, pre-drilling and countersinking the holes. This method mitigates splitting, which was an issue I faced earlier. Ensure everything is clamped securely before driving in the screws.
Step 5: Build the Back Panel
Assemble the back panel using four boards with two cross supports. Use spacers to ensure even gaps between the boards and secure them with screws. Once the back panel is complete, attach it to the back legs using the same method as before.
Step 6: Create the Seat
Start by adding the front seat slat, which helps with comfort. Measure the distance between the back panel and the front slat, subtracting gaps for the other slats. Cut and install the remaining seat slats, ensuring to maintain even spacing.
Step 7: Final Touches
Once everything is assembled, remove the copper base and prepare it for finishing. Use a file to smooth any solder joints and wipe down the base with acetone before applying a self-etching primer followed by flat black paint.
Step 8: Plug the Screw Holes
Utilize a plug cutter to create plugs from the same wood, allowing them to blend seamlessly into the chair. After trimming the plugs flush, sand the entire chair up to 180 grit, ensuring all edges are smooth.
Step 9: Finishing the Chair
Since the thermally modified ash is highly rot-resistant, I chose to let it develop a natural gray patina over time. This decision minimizes the need for ongoing maintenance while still enhancing the chair’s aesthetic.
With the base reattached, your modern Adirondack chair is complete! If you’re interested in building your own, detailed plans are available here: https://craftedworkshop.com/store/diy-modern-adirondack-chair-plans.