Tip #61
Build a Lawn/Patio Chair
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Instructions

1. Cut all the stock to size according to the List of Materials. (Make your size adjustment now if you're building a variation of our chair.) Care should be taken to avoid knots, especially when using treated lumber.

2. Use a shaper head and fence to radius two edges of the seat supports (B). A 1/2-inch radius is preferable, but if a router is used, a smaller radius is acceptable.

3. Transfer the patterns (from the plan grid) for back supports (A) and seat supports (B) to large piece of paper. Lay the back and seat supports on the pattern and mark, cut, drill, dowel and glue at the correct angle to fit your pattern.

4. Use a bandsaw or jigsaw to cut the newly created "side" -- back (A) and seat (B) sub-assembly -- to the correct shape. Sand for final assembly.

5. Transfer the pattern for the front legs (C) and the back legs (D) to paper. Lay the front and back legs on the pattern and cut, drill for end dowels, and sand for final assembly.

6. Drill, dowel, and glue the legs (C & D) to the side sub-assemblies at the proper angles according to the pattern.

7. Attach the side/leg assemblies to the spreaders (E) with 3/8-inch dowels (G) and glue. Use extra care at this stage to insure squareness.

8. Attach slats (F) to the back supports (A) with screws (H). Use a 1/2-inch wood block to space slats parallel and at 1/2-inch intervals.

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