This woodworking project, created by GET HANDS DIRTY, is a fantastic way to enjoy the outdoors without leaving home.
With just a handful of tools, anyone can create these outdoor folding chairs. The design allows for comfort and functionality, making it perfect for lounging in the sun. Let’s dive into the step-by-step process of building these chairs.
Step 1: Lumber Preparation
Before starting, you’ll need to prepare your lumber. While you can purchase ready-to-use wood from your local lumber store, using rough pine beams can save you some money if you have them on hand. However, opting for a more durable wood, like cedar, is advisable for outdoor use.
Begin by cutting the beams at the center. This step is crucial as large boards cut closer to the tree’s center are prone to cupping. By cutting them, you relieve some pressure and improve the wood’s stability. Next, cut the beams in half lengthwise. This makes it easier to joint and flatten the smaller stock.
Using a bandsaw, make these cuts quickly and efficiently. You may notice slight rounding in the cuts, but don’t worry—there’s plenty of wood to work with. After cutting, use a benchtop jointer to flatten and square two faces of the wood. This is essential for ensuring a proper fit later on.
Once you have two adjacent faces nice and square, feed the wood through a thickness planer to achieve perfectly flat and parallel surfaces. Plan the wood into two different thicknesses: 27mm for the leg and arm structure and 22mm for the seat and back panels. This step is crucial for maintaining the structural integrity of the chairs.
Step 2: Building the Template
Now that your wood is prepared, it’s time to create a template. This template will guide your cuts and ensure consistency throughout the project. You can download a free template from the creator’s website.
After assembling the template, lay it out over the wood, avoiding knots and cracks, which can weaken the structure. Identify all parts clearly to prevent confusion during assembly. You’ll need several pieces for two chairs, and you can cut them in various ways depending on the tools available.
If you lack stationary power tools, don’t worry! You can use a jigsaw or circular saw instead. Just be mindful of the order of cuts; some cuts should be made before others. For instance, avoid cutting certain lines first that would leave smaller pieces difficult to handle.
Step 3: Cutting the Pieces to Size
Using clamps will help keep the wood steady while cutting. Take your time to ensure accuracy, especially when using a handsaw. If you have access to larger tools like a table saw or bandsaw, your cutting process will be much quicker.
After cutting all the trapezoidal pieces, refine their shapes to keep them straight, maintaining the template sizes and angles. A power sander can simplify this task, but a board with coarse sandpaper will work as well. Don’t forget to get your body moving during this process!
Step 4: Preparing the Seat and Back Panels
Next, focus on the seats and backs. You’ll need to glue the boards in pairs to create wider panels. Decide which pieces go together and place their edges facing up on a workbench vise.
The trick here is to plane the two edges together as one, ensuring they match perfectly. After flattening the edges, create slight ramps at the front and back to simplify the clamping process. This allows you to use fewer clamps while ensuring a strong bond.
Make sure to use exterior wood glue. Apply enough glue so that a small amount squeezes out along the joint when pressed together. After the glue has dried, trim the panels to their final size and sand them smooth for comfort.
Step 5: Joining the Parts Together
To join the chair parts, you will use dowels. A doweling jig can make this process easier and more reliable. If you don’t have one, you can create a simple jig using scraps of wood. Drill holes into the hardwood scrap to create a reference for your dowel placements.
Mark specific measurements on the chair pieces where the dowels will be placed. This ensures the side assemblies are similar. Use your jig to drill holes at the marked spots, ensuring a snug fit for the dowels.
After checking for fit, glue the parts together using clamps to hold them in place. Repeat this process for the leg assembly, considering using thicker dowels for added strength.
Step 6: Assembling the Chair
Next, grab the template pieces and mark where to drill holes for screws. Start by drilling larger holes to later plug with dowel rods, hiding the screw heads for a cleaner look. Some holes will be drilled all the way through for the pivot points of the folding mechanism.
Once all components are ready, assemble the legs, side assemblies, and seat boards. If you lack a workbench vise, enlist a helper to keep everything secure while you screw the pieces together. The gap between the boards can be adjusted to your preference.
Step 7: Final Touches and Finish
Connect the assembled parts with Chicago bolts or sex bolts, cutting the stainless steel threaded rod to size as needed. Ensure the support piece is attached securely, and fill any screw holes with wood plugs for a polished finish.
Finally, round over any sharp corners and prepare to apply your finish. It’s easier to finish the pieces separately, so disassemble if necessary. Choose a durable finish meant for outdoor use, following the manufacturer’s recommendations.
Congratulations! You have successfully built your own outdoor folding chair. This project not only enhances your outdoor space but also provides a sense of accomplishment. Remember, even with minimal tools, you can achieve great results. Enjoy your new chairs!