Cedar Patio Chair

Hello Makers,

I was in need of some new patio chairs. I found a similar design I liked online, but the cost was way too high. It seemed feasible to make in my garage, so I got to work!

Tools:

Inventor (CAD software)

Mallot

Plug Cutter

Drill

Flush Cut Saw

Orbital Sander with 60/120/320 Grit

Router with Chamfer Bit

Table Saw

Measuring Tape

Protractor

Mitre Saw

Drill Press

Clamps

Plug Cutters

Drill Bits

Drill Block

Material:

Cedar 2x6

Wood Glue

Tung Oil

Clear Coat Polyurethane

Patio Cushions

Dowels

Screws

• 3D model in inventor or a CAD software of your choice.
• Procure cushions beforehand because design will be driven by those dimenions.
• Create detailed drawings to make construction a breeze!

This chair has some interesting geometry, so getting everything right in the digital world is important. The plan is to use screws and wood glue for the joints. Plugs will then be used to cover the fasteners and make it more aesthetically appealing.

• Cut wood to length using a mitre saw. A mitre saw is also used to cut the proper angles.
• There are some interesting angles with this design. To achieve the lengthwise angle cut, we use a table saw that is set to the proper angle with a digital protractor.
• Notch the upright and horizontal boards (picture 4) with a mitre saw (set depth on mitre saw to half the width of the board). This will create a strong joint when glued and screwed together.

Take your time and make sure your cuts are right.

• Join the notched boards together with wood glue and screws. Clamp until dry.
• To join the legs to the notched boards, dowels are utilized as shown in the 4th picture (red lines indicate dowel location).
• I found it easiest to build the sides first then clamp the horizontal boards between the sides. I would do one at a time using wood glue, screws and plugs.

Sequence for the joint:

1. Countersink 1/2" hole.
2. Drill 1/8" pilot hole for screw.
3. Apply wood glue on board ends.
4. Place into correct position and clamp.
5. Screw in 2.5" length screws.
6. Wipe up the glue squeeze out.
7. Apply wood glue into countersunk hole and insert plug. Ensure wood grain is aligned correctly.
8. When glue is dry, cut plug excess off with a flush cut saw.
9. Sand smooth.

• Router sharp edges with a chamfer bit.
• Sand entire assembly. 60/120/320
• Rub Tung oil over entire assembly. Let dry.
• Spray two coats of exterior polyurethane to completely seal the cedar. This will preserve the natural color of the wood.

TIP: Use a drill block to achieve perpendicular holes for the plugs.

Thanks for following along!