How to Make a Wooden Outdoor Deck Chair with a Weatherproof Finish
Building a wooden outdoor deck chair is a rewarding project that combines functionality with craftsmanship. With the right materials and finishing techniques, you can create a comfortable, durable chair that stands up to the elements. Here’s a step-by-step guide on how to build a high-quality wooden deck chair with a weatherproof finish.
Materials and Tools
Before starting, gather the following materials and tools:
Materials:
- Weather-resistant hardwood (cedar, teak, or redwood are ideal choices)
- Wood screws (stainless steel or galvanized)
- Wood glue (exterior-grade)
- Sandpaper (80-grit, 120-grit, and 220-grit)
- Outdoor wood sealant or waterproof finish (e.g., marine varnish, polyurethane, or tung oil)
- Wood filler (if needed)
- Outdoor cushions (optional for added comfort)
Tools:
- Saw (circular saw or miter saw)
- Drill with screw bit
- Screwdriver or drill
- Measuring tape
- Carpenter’s square
- Paintbrush or cloth for finishing
- Clamps (for holding pieces in place while assembling)
Step 1: Prepare the Design and Measurements
Before cutting the wood, it’s essential to have a clear design. Here’s a simple layout for a deck chair:
- Seat dimensions: 18 inches deep by 20 inches wide.
- Backrest dimensions: 32 inches high.
- Armrests: 22 inches long and 6 inches wide.
Sketch your design, taking into account the chair’s ergonomic angle and comfort. Use a carpenter’s square to ensure all angles are correct.
Step 2: Cut the Pieces
Use your saw to cut the following components:
- Seat slats: Cut 5-6 pieces, each around 20 inches long, depending on your design. These will be the horizontal seat supports.
- Backrest slats: Cut around 4-5 pieces, each around 32 inches long. The slats will be arranged vertically for support.
- Legs: Cut four leg pieces (2 for the front and 2 for the back). The back legs should be cut at a slight angle to provide the necessary reclining angle (approximately 15-20 degrees).
- Armrests: Cut two armrest pieces at 22 inches long and 6 inches wide.
If you are creating a chair with a slanted backrest, the angle for the back legs will need to be considered to ensure the correct angle for comfort.
Step 3: Sand and Smooth the Wood
Before assembling the chair, sand the pieces thoroughly to smooth out any rough edges or imperfections. Begin with an 80-grit sandpaper and move up to 120-grit for a smoother finish. Finish with a 220-grit sandpaper to prepare the wood for staining and sealing.
Make sure all edges are rounded, especially around areas where you will be sitting or resting your arms, for added comfort.
Step 4: Assemble the Frame
Start by attaching the legs to the seat frame. Use wood screws and wood glue for a secure hold. Here’s how:
- Attach the front legs: Screw the front legs into the two front corners of the seat frame.
- Attach the back legs: The back legs should be screwed into the back corners at an angle, forming the reclined back of the chair.
- Install the cross supports: Depending on your design, you may add cross supports between the legs for added strength.
- Fix the armrests: Attach the armrests to each side of the chair, ensuring they are at a comfortable height. Use screws and wood glue to secure them in place.
Ensure the chair frame is square and level as you assemble it. Use a carpenter’s square to double-check all angles.
Step 5: Attach the Seat and Backrest Slats
Once the frame is assembled, it’s time to attach the seat and backrest slats:
- Seat slats: Place the slats across the frame evenly, leaving small gaps for drainage. Attach each slat with screws, making sure they are securely fastened but not too tight, allowing some room for expansion and contraction due to moisture.
- Backrest slats: Similarly, position the slats for the backrest, leaving gaps for ventilation. Screw them into place vertically along the backrest supports.
Check that everything is aligned before tightening the screws fully.
Step 6: Apply the Weatherproof Finish
To protect your deck chair from the elements, applying a weatherproof finish is crucial. Here are a few types of finishes you can use:
Marine Varnish: This is ideal for outdoor furniture exposed to rain and UV rays. It forms a tough, water-resistant coating that enhances the wood’s natural color and protects it from moisture.
Tung Oil: For a more natural, matte finish, tung oil penetrates the wood, providing moisture resistance and flexibility.
Polyurethane: For heavy-duty protection, an outdoor-grade polyurethane finish is a great option. It offers a glossy sheen and adds a protective layer against rain, UV rays, and temperature fluctuations.
Before applying any finish, ensure the wood is clean and dry. Apply the finish with a paintbrush or cloth in long, even strokes. Allow it to dry between coats, lightly sanding with 220-grit sandpaper after each coat. Apply 2-3 coats for optimal protection.
Step 7: Final Touches and Cushioning
After the finish has fully dried, you can add cushions or pillows for added comfort. Be sure to choose outdoor cushions designed to withstand exposure to weather, or opt for removable covers that can be brought inside when not in use.
Step 8: Maintenance Tips
To keep your outdoor deck chair in good condition, here are a few maintenance tips:
- Clean regularly: Wash the chair periodically with soap and water to remove dirt, leaves, and debris.
- Reapply finish: Over time, the protective finish may wear off, especially in areas exposed to heavy sunlight. Reapply the finish as needed to maintain the weatherproof coating.
- Store in extreme weather: During extreme weather conditions (e.g., winter), consider storing the chair in a sheltered spot to prolong its lifespan.
Conclusion
Building a wooden outdoor deck chair is a rewarding and practical DIY project. By choosing durable, weather-resistant wood and applying a high-quality weatherproof finish, you can ensure your chair lasts for years, offering comfort and style on your patio or deck. Take your time with each step, and enjoy the satisfaction of creating a beautiful, functional piece of outdoor furniture.
For more woodworking projects and techniques, check out Teds Woodworking Course here.
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