Creating a wooden outdoor lounge chair with cushions can be a fun and rewarding woodworking project. Not only will you end up with a custom piece of furniture, but you’ll also have the satisfaction of creating something functional and durable. This project will require some basic woodworking tools and skills, as well as some fabric and foam for the cushions. Here’s a step-by-step guide to help you get started.
Materials and Tools Needed:
Materials:
- Pressure-treated lumber (cedar, pine, or teak are good options for outdoor furniture)
- Outdoor-grade screws (2.5″ or 3″)
- Wood glue
- Outdoor wood finish or sealant (for weatherproofing)
- Foam cushions (cut to size)
- Outdoor fabric for cushion covers (e.g., Sunbrella)
- Upholstery staples or a staple gun
- Cushion filling (optional)
Tools:
- Circular saw or table saw
- Drill with drill bits
- Screwdriver or impact driver
- Measuring tape
- Sandpaper or power sander
- Clamps
- Staple gun
- Sewing machine (optional for making cushion covers)
Step 1: Plan and Measure
Before you start cutting any wood, it’s important to plan the design and measurements of the chair. A typical outdoor lounge chair will have a width of around 30-36 inches, a depth of 30-40 inches, and a height of about 35 inches. Make sure to account for the thickness of the wood when calculating the dimensions. Draw out your design, including the seat, backrest, armrests, and legs.
Consider the seat’s height for comfort—around 16-18 inches from the ground is common. The backrest should slope slightly for a comfortable reclining position.
Step 2: Cut the Wood
Once your measurements are set, begin cutting the wood. Here’s a basic breakdown of the cuts needed for the frame:
- Legs (4 pieces) – Cut four legs, typically around 16-18 inches long.
- Seat Support (2 pieces) – Cut two pieces that will run across the width of the chair to support the seat slats.
- Backrest Supports (2 pieces) – Cut two vertical pieces that will hold the backrest.
- Backrest Slats (6-8 pieces) – Cut several slats to make up the backrest, usually 2-4 inches wide.
- Seat Slats (5-6 pieces) – These slats will form the base of the seat.
Use a circular saw or table saw for clean, straight cuts. Sand the edges of each piece to ensure a smooth finish.
Step 3: Assemble the Frame
Start with the legs: Attach the four legs to the seat supports, ensuring they are square and evenly spaced. Use wood glue and screws for a secure connection. It’s a good idea to clamp the pieces together while the glue dries for extra stability.
Attach the backrest supports: Once the seat is assembled, attach the two vertical pieces that will support the backrest. These should be placed at the back corners of the chair frame. Make sure they are level and securely fastened.
Install the backrest slats: Space the backrest slats evenly and attach them to the backrest supports using screws and wood glue. These slats should be angled slightly for comfort, so make sure the bottom slats lean back at around a 10-15 degree angle.
Attach the seat slats: Lay the seat slats across the seat support beams. Space them evenly, and secure them with screws or nails. Make sure the slats are level and tightly attached.
Step 4: Sand and Finish the Wood
To prepare your wooden frame for outdoor use, thoroughly sand all surfaces to remove any rough spots and splinters. A power sander or sanding block will make this job easier.
After sanding, apply an outdoor wood finish or sealant. This will help protect the wood from the elements, particularly if your chair will be exposed to sun, rain, or humidity. Apply several coats for maximum durability, following the manufacturer’s instructions.
Step 5: Make or Buy Cushions
Now it’s time to focus on the cushions. You can either make your own cushions or purchase pre-made ones. If you’re making your own:
- Cut the foam to the desired size for both the seat and backrest. A density of 2-3 inches thick is common for comfortable seating.
- Sew the cushion covers using outdoor fabric that resists water and fading (like Sunbrella). Make sure the covers are slightly larger than the foam to allow for easy stuffing and a snug fit.
- Insert the foam into the cushion covers. If desired, you can also add a layer of batting for extra softness.
- Staple or sew the fabric closed at the edges.
Step 6: Attach the Cushions
Once your cushions are ready, place them onto the seat and backrest of the chair. Some people prefer to secure the cushions with ties, while others simply let them rest in place. If you want the cushions to be removable for easy cleaning, use Velcro or hook-and-loop strips to attach them to the chair frame.
Step 7: Final Touches
Once the frame and cushions are complete, do a final check for any loose screws or unfinished edges. Touch up any spots that need additional sanding or finishing.
Step 8: Enjoy Your New Chair!
Place your new wooden lounge chair on your patio, deck, or in your garden, and relax! The cushion covers should be easy to remove and wash, and with the outdoor wood finish, your chair will be weather-resistant for years to come.
Conclusion
Building a wooden outdoor lounge chair with cushions is a great way to create a custom piece of furniture that fits your style and needs. By following these steps, you can create a comfortable, durable chair that will withstand outdoor conditions and provide a cozy spot to relax. Don’t forget to add some throw pillows or blankets for extra comfort, and enjoy your new lounging space!
For more detailed plans and guides on woodworking projects like this, check out Ted’s Woodworking Course here: Teds Woodworking Course.