Making a wooden deck chair requires careful planning and attention to detail, but with the right materials and tools, it’s a rewarding project. Here’s a step-by-step guide to creating a sturdy and comfortable wooden deck chair.
Materials Needed:
- Wood (Teak, Cedar, or Redwood are popular choices for outdoor furniture due to their durability)
- Wood screws (Corrosion-resistant)
- Wood glue
- Sandpaper (Coarse and fine grit)
- Outdoor wood finish or sealant (to protect the wood from the elements)
- Measuring tape
- Saw (Circular saw or miter saw for straight cuts)
- Drill and drill bits
- Clamps
- Screwdriver
- Wood filler (optional, to fill any screw holes)
- Wooden slats (for the seat and backrest)
- Hinges (if you’re planning on making the chair foldable)
Step 1: Plan and Cut the Wood Pieces
First, you need to plan the dimensions of your deck chair. The size of the chair can vary depending on your preferences, but a typical deck chair is around 24 inches wide, 28 inches deep, and 36 inches tall when finished.
You will need the following parts:
- Two side rails – These will form the sides of the chair, giving it its shape. They are typically around 36 inches long and 4 to 6 inches wide.
- Back support rails – Two pieces that will hold the backrest slats. These should be about 24 inches long.
- Seat rails – Two pieces for the front and back support of the seat. They should be around 20 to 22 inches long.
- Seat slats – About 5 to 6 slats that will form the seat of the chair, typically 2 to 3 inches wide and 20 to 22 inches long.
- Backrest slats – Around 5 to 6 slats, similar to the seat slats, but a bit longer (24 inches).
- Leg supports – Four small pieces that will hold the chair’s legs, usually 4 inches long.
Using your saw, cut the wood according to your measurements.
Step 2: Sand the Wood
Once your pieces are cut, use coarse sandpaper to smooth out rough edges. Follow with fine-grit sandpaper to achieve a smooth surface, which will make finishing easier and more effective.
Step 3: Assemble the Frame
Attach the seat rails to the side rails: Start by securing the seat rails to the side rails. Use wood glue to hold them in place, and then drill pilot holes and secure them with screws. Make sure that the frame is square before tightening the screws.
Attach the backrest support rails: Similarly, attach the backrest support rails to the side rails. Use wood glue and screws to ensure the backrest rails are securely attached.
Step 4: Attach the Seat and Backrest Slats
Position the seat slats: Place the seat slats evenly across the seat rails. Start from one side and work your way across. Make sure there’s a small gap (about ¼ inch) between each slat to allow water to drain. Use screws or nails to secure each slat to the seat rails.
Position the backrest slats: Repeat the process for the backrest. Attach the slats to the backrest support rails, leaving a gap between them for drainage and flexibility. If you want to have an adjustable backrest, you can attach it with hinges, allowing it to recline.
Step 5: Install the Legs
If you’re not making the chair foldable, you can install the legs by screwing the leg supports into the side rails. If you want a foldable chair, you can add hinges to allow the legs to collapse when not in use.
Step 6: Apply the Finish
After the chair is assembled, apply an outdoor wood finish or sealant to protect it from the elements. This will enhance the durability of the chair, especially if it’s being used outdoors.
Step 7: Final Touches
Once the finish has dried, go over the chair again with sandpaper to remove any rough patches, and then add a final coat of finish for extra protection.
Step 8: Enjoy Your Wooden Deck Chair
Once the wood is fully dry and the finish is set, your deck chair is ready for use. Add some comfortable cushions or pillows for extra comfort and enjoy your new piece of outdoor furniture.
By following these steps, you can create a beautiful and functional wooden deck chair for your outdoor space.
For more woodworking projects, check out Ted’s Woodworking Course here.