Cutting Materials to Size
Cut your 2x4s and 2x6s to the correct lengths, ensuring precision. Verify measurements to avoid assembly issues. Mark angles on base pieces using an angle gauge, then cut with a circular or track saw.
For half-lap joints, clamp support pieces together and use a circular saw set to the proper depth. Make several scores to remove excess wood, then clean up with a chisel.
Secure the first two base pieces with glue from underneath. Use a pocket hole jig for hard-to-reach areas. After gluing and clamping, reinforce with screws.
Prepare the seat support by measuring the stretcher angle and securing it with pocket holes and glue. For the center seat support, cut it to sit flush with the base angles, drill pilot holes, and screw in place.
Cut slats uniformly using a stop block. Pre-drill pocket holes and attach with glue, maintaining even gaps. Sand surfaces you'll touch most, focusing on tops and edges. 120-grit sandpaper works well.
Add feet and optional wheels. Apply a clear finish or stain to protect against the elements.
Assembling the Base Frame
Align pre-cut base pieces using butt joints. Apply wood glue to joint surfaces and use quality wood screws. Drill pilot holes before inserting screws to prevent splitting.
Ensure base pieces lie flat, with angles aligned correctly. Use a square to check for 90-degree angles (or your desired angle). Clamps help keep everything steady during assembly.
Attach the center support to reinforce the structure. After gluing and screwing the symmetrical base into one unit, check for any unintended gaps.
Attaching Slats and Supports
Begin with pre-cut seat slats, aiming for a consistent pattern with uniform gaps. Use a spacer for evenness. Secure slats using pocket screws and wood glue.
Install backrest supports at the right angle for optimal comfort. Consider sturdy hinges for an adjustable backrest.
Align the backrest with seat slat contours for a cohesive look and feel. Double-check symmetry for comfort and appearance.
Examine your setup and gently shake the chair to ensure stability. Verify there are no loose components.
Sanding and Finishing
Sand areas that will contact the body, using 120-grit sandpaper on tops and edges. Focus on comfort rather than excessive smoothness.
Use a sprayer for efficient finishing, especially with slat gaps. Choose a high-quality, weather-resistant finish to maintain appearance through various conditions.
Apply in even strokes, maintaining consistent distance to avoid pooling. Keep a cloth handy for excess finish, particularly in corners and joint undersides.
Allow thorough drying before adding cushions or testing.
Your attention to detail transforms basic materials into a valued piece of furniture. Enjoy the satisfaction of seeing your work come together, knowing every decision improves both function and aesthetics.
- Simpson Strong-Tie. DSV Deck Drive wood screws.
- Graco. Cordless airless sprayer.
- Behr. Ultra Pure White paint.