This project was built and designed by Josh Wright. It’s a creative, low-cost outdoor lounger chair made entirely from one 2×6 board—perfect for those looking to stretch their materials without sacrificing design or strength.
Josh’s video highlights how even a single piece of lumber can become a stylish, supportive piece of furniture with the right planning and joinery. The lounger features clean lines, functional angles, and a natural finish that complements any outdoor setting.
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Project Concept and Approach
The idea behind this lounger is to maximize usability and aesthetics using as little material as possible. By working within the constraint of a single board, Josh puts a spotlight on smart layout, minimal waste, and efficient construction.
The final piece is simple but visually interesting, relying on contrasting angles, refined joinery, and a clean finish. It’s approachable enough for DIYers on a budget and clever enough to catch the attention of seasoned woodworkers.
Breaking Down the Lumber
Josh begins by cutting the 2×6 board into multiple strips. Each strip is assigned a role in the structure—some become the angled sides, others act as cross braces, and the rest are milled into thin seat slats.
This first round of cuts is crucial. Each angle is planned for both strength and style, with 30-degree and 60-degree angles forming the sides and back, and a standard 90-degree cut for the lower brace.
Joinery and Assembly Strategy
Once the pieces are prepared, Josh moves on to joinery. He opts for a mix of bridle joints and half-laps to keep the frame sturdy without adding hardware-heavy connections. These joints offer a traditional, shop-made look that enhances the chair’s overall quality.
Dowels are used in the bridle joints—not Josh’s first choice for appearance, but they help lock the pieces in place during glue-up. The sides are assembled first, ensuring everything is square and aligned before moving forward.
Seat Slats from Leftover Lumber
After the frame is glued and dried, attention turns to the seat. Josh uses the remaining sections of the 2×6 to cut quarter-inch thick slats. Each slat is chamfered on the edges to give it a more refined appearance and better visual spacing once installed.
This use of leftover material minimizes waste and keeps the entire project within the budget and size of a single board. It’s a great example of maximizing every inch of stock.
Attaching the Slats
With the slats ready, Josh glues them across the seat section of the frame. He adds a deeper rabbet in the rear support area to accommodate the slats where weight is concentrated—an easy adjustment that makes a big difference in comfort and support.
Spacing is done by eye, and the slats are carefully aligned before being glued into place. The result is a wide, supportive seat surface that looks sharp and feels solid.
Sanding and Finishing
To complete the project, the entire chair is sanded using fine-grit sandpaper to remove any sharp edges and prep the surface for finishing. This step also helps clean up any glue residue from assembly.
Josh applies amber shellac to the wood, giving it a warm glow and protecting it from light wear and moisture. It’s a fast-drying finish that enhances the grain without darkening the wood too much.
Stability and Testing
With the build complete, Josh gives the lounger a real-world test by sitting down and shifting his weight. The seat holds up without issue, and the frame remains stable despite the thin slats.
He does note that the angled legs have a tendency to push away under pressure. However, the inclusion of the bottom brace helps counteract this movement, making the chair much more stable overall.
A Creative Use of Limited Materials
This lounger chair project is a perfect example of how thoughtful design and joinery can turn basic materials into something beautiful and practical. Josh shows that even with just a single 2×6, it’s possible to build a sturdy, stylish piece of outdoor furniture.
The techniques used—bridle joints, smart angles, and efficient layout—make it a great learning project for newer woodworkers. And for anyone looking to build furniture on a budget, it’s hard to beat the material cost and payoff of this design.
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