This project was built and designed by Josh Wright. It revisits a previous build—a roll-up chair—with a fresh focus on aesthetics, strength, and smarter materials that improve both comfort and durability.
Josh’s first attempt at a roll-up chair worked surprisingly well from a functional standpoint but fell short in the looks department. This second version takes the same concept and refines it, addressing previous issues while experimenting with better joinery, reclaimed materials, and a surprising discovery that changed the build’s direction.
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Reworking the Original Design
The basic idea behind the roll-up chair is clever: a flexible set of slats connected by rope or strapping, allowing the chair to collapse and roll for portability. While the original worked, its rough look and limited comfort left room for improvement.
This time around, Josh set out to build something that not only functioned well but also looked more intentional. Cleaner edges, better material choices, and more thoughtful joinery were top priorities from the start.
Upgrading to Solid Pine
One of the biggest changes in this version was moving away from plywood and choosing solid pine instead. Plywood presented issues in the earlier design—mainly splintering and unattractive edges—so Josh turned to reclaimed pine with visible texture and age for a more organic look.
The wood was cut into strips, trimmed to length, and sanded to remove surface stains while still retaining the reclaimed character. This step gave each piece a more polished appearance without stripping away the rustic feel.
Building with Interlocking Joinery
To build the framework of the chair, Josh returned to a Z-style layout. This setup creates a reliable shape and provides natural tension points to hold the chair open under weight.
The key to the build is a series of dado cuts along each slat. These grooves help seat the support material that links all the slats together, creating a flexible but stable structure. Each cut is measured precisely to ensure the slats remain evenly spaced once the chair is rolled out.
A Chance Yard Sale Find
Originally, rope was going to be the primary method for connecting the slats. But while visiting a local yard sale, Josh found a roll of pallet banding—a material usually used for shipping and packaging. That discovery completely shifted the approach.
Pallet banding proved to be stronger, thinner, and more reliable than rope. It doesn’t stretch, which helps the chair maintain its shape, and it’s easy to tension properly. Once tested, it became clear that this material was a major improvement over the original plan.
Integrating Banding for Strength
With the pallet banding in hand, Josh changed course. Instead of threading rope through each slat, two runs of pallet banding were fastened to the outer edges. This gave the chair a much cleaner appearance and greater resistance to sagging.
The rope wasn’t abandoned entirely. It was still used to provide a little flexibility and grip, but the banding became the backbone of the entire build. This adjustment helped the chair stay upright and distribute weight more evenly when in use.
Final Shape and Seating Comfort
Once assembled, the chair didn’t look especially comfortable—but that changed quickly once weight was applied. As someone sits, the slats compress slightly and create a curved seating surface that molds naturally to the body.
Compared to the original version, this chair felt much sturdier. The added support from the banding and the denser wood made the final piece feel solid and reliable, even when under significant pressure.
Dealing with Roll-Up Behavior
One small issue remained: when not in use, the chair had a tendency to roll itself back up. The tension in the banding wanted to pull everything back into a tight coil, making it a challenge to keep the chair open and ready for use.
Josh came up with a simple solution—tie the ends of the rope together. This created just enough resistance to prevent the chair from curling up when empty, keeping it in place and functional without adding any extra hardware.
A Project Built on Problem-Solving
The final chair is a big leap forward from the original design. It’s stronger, cleaner, and more visually appealing thanks to improved material selection, new joinery techniques, and that lucky find at a yard sale.
This project is a great example of how woodworking often involves on-the-fly adjustments. From the choice to ditch plywood, to the unexpected use of pallet banding, every change in this build was made with function and appearance in mind.
Takeaways for Future Projects
For woodworkers looking for something unique and practical, this project checks a lot of boxes. It folds up neatly, supports full body weight, and uses affordable materials that can often be reclaimed or found secondhand.
Josh’s approach highlights the value of adapting on the go and letting the project evolve naturally. The result is a roll-up chair that balances simplicity and engineering, all while looking good enough to display or use daily.
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