These simple-to-make chairs are a great addition to any backyard or deck--and even without a pillow, they are surprisingly comfortable. A great way to add seating to your backyard living space when you have very little time and money.
* MATERIALS 17 linear feet of 2 x 4 pine 30 linear feet of 1 x 4 pine * HARDWARE 95 2 1/2" wood screws 4 3 1/2" carriage bolts 4 3 1/2" lag screws * SPECIAL TOOLS AND TECHNIQUES Bar clamps * HARDWARE 50 1 5/8" wood screws
340 1 1/4" (3d) finish nails
INSTRUCTIONS
* Building the Seat
1. Cut one Seat Front (A) from 1 x 4 pine, measuring 20 inches.
2. Cut two Seat Sides (B) from 2 x 4 pine, each measuring 19 inches.
3. Position the two Seat Sides (B) on edge, parallel to each other and 17 inches apart. Fit the Seat Front (A) over the ends of the Seat Sides (B), as shown in figure 1. Apply glue to the meeting surfaces, and screw through the Seat Front (A) into the ends of the Seat Sides (B), using two 2 1/2-inch wood screws on each joint.
[FIGURE 1 OMITTED]
4. Cut five Seat Slats (C) from 1 x 4 pine, each measuring 20 inches.
5. Place the seat assembly [Seat Front (A) and Seat Sides (B)] on a flat surface. Position the five Seat Slats (C) over the assembly, as shown in figure 2. The first Seat Slat (C) should be set back 1/2 inch from the face of the Seat Front (A), and the Seat Sides (B) should remain exposed at the other end. Screw through the Seat Slats (C) into the Seat Sides (B), using two 2 1/2-inch wood screws on each joint.
[FIGURE 2 OMITTED]
* Making the Back
1. Cut two Back Supports (D) from 2 x 4 pine, each measuring 14 1/2 inches.
2. Cut five Backs (E) from 1 x 4 pine, each measuring 20 inches.
3. Position the two Back Supports (D) on a flat surface, parallel to each other and 13 inches apart. Position one Back (E) over the two Back Supports (D), as shown in figure 3. The first Back (E) should overhang the ends of the two Back Supports (D) by 1 inch. Apply glue to the meeting surfaces, and screw through the Back (E) into each of the Back Supports (D), using two 2 1/2-inch wood screws on each joint.
[FIGURE 3 OMITTED]
4. Repeat step 3 four times to attach the remaining four Backs (E) to the two Back Supports (D).
* Making the Sides
1. Cut two Arms (F) from 1 x 4 pine, each measuring 21 inches.
2. Using figure 4 as a guide, shape the one Arm (F) by eliminating cutting off the shaded portions. Use the shaped Arm (F) as a pattern to cut the remaining Arm (F).
[FIGURE 4 OMITTED]
3. Cut four Arm Supports (G) from 2 x 4 pine, each measuring 24 inches.
4. Position two Arm Supports (G) face down on a level surface, parallel to each other and 12 inches apart. Place one Arm (F), uncut edge down, over the ends of the two Arm Supports (G), as shown in figure 5. The Arm (F) should overlap each of the Arm Supports (G) by 1 inch on each side. Apply glue to the meeting surfaces, and screw through the Arm (F) into the end of the Arm Supports (G), using two 2 1/2-inch wood screws on each joint.
[FIGURE 5 OMITTED]
5. Repeat step 4 to construct another side, using the remaining two Arm Supports (G) and the remaining Arm (F).
* Attaching the Arms
1. Draw a line across the inside of each Arm Support (G), 18 inches from the unattached end. This will be the placement line for the next step.
2. This step is easier with a helper. The object is to clamp the assembled seat between the two side assemblies (as shown in figure 6), then secure the seat with carriage bolts. The top of the seat should be positioned at the placement marks that you drew on the Arm Supports (G). The front Arm Supports (G) should be positioned 2 inches from the front of the seat assembly. When the sides are in position, clamp the two sides and seat assemblies tightly together, using bar clamps.
[FIGURE 6 OMITTED]
3. Drill a hole slightly larger than the diameter of the 3 1/2-inch carriage bolt through the center of each of the Arm Supports (G) and into the Seat Sides (B). Then insert a 3 1/2-inch carriage bolt through each of the holes. Tighten the bolts securely.
* Adding the Back
1. Insert the back assembly between the two assembled sides. The Backs (E) should face the front of the chair, and the recessed end of the two Back Supports (D) should be at the top of the chair. To make the chair more comfortable, tilt the back assembly at a slight angle--out at the top and in at the bottom. The tilt angle is determined by the width of the 2 x 4 on the Arm Supports (G) and the back of the Arm (F).
2. When you have the back fitted perfectly, secure the assembly with bar clamps. Screw through the Arm Supports (H) into the Back Supports (E), using two 2 1/2-inch wood screws. Then insert a 3 1/2-inch lag screw through the Arm Supports (H) and into the Back Supports (E).
* Finishing
1. Fill any cracks, crevices, or screw holes with wood filler.
2. Sand the completed chair thoroughly.
3. Paint or stain the chair the color of your choice--or simply leave it the natural color.
CUTTING LIST Code Description Qty. Materials Dimensions A Seat Front 1 2 x 4 pine 20" long B Seat Side 2 2 x 4 pine 19" long C Seat Slat 5 1 x 4 pine 20" long D Back Support 2 2 x 4 pine 14 1/2" long E Back 5 1 x 4 pine 20" long F Arm 2 1 x 4 pine 21" long G Arm Support 2 2 x 4 pine 24" long
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