How to Make Bent Plywood Chairs

Building the Jigs

• 1

  Sketch a profile line on one particle board using a permanent marker for the upper section of the chair. The back section will be approximately 28 inches in length and the seat section will be approximately 20 inches in length. For curved seat fronts or lumbar support, these lines can be curved. The line's total length must not extend beyond 4 feet.

• 2

  Sketch a profile line on the second particle board for the chair's base. The line will appear as an upside down "U". The chair will attach to the base at the flat section of the inverted "U" that is approximately 6 inches long. The two ends of the "U" should not exceed 32 inches in distance from one another. Total line length must not be more than 4 feet.

• 3

  Identify the through-hole locations. Within the base jig, there will be seven pairs of holes and in the upper jig there will be nine pairs of holes. The profile line will be located directly between each pair of holes. There will be an exact spacing of ½ inch between each pair of holes. Make certain to have a pair of holes located at the middle, end and beginning of each profile curve.

• 4

  Use a drill and 3/8-inch bit to make the through-holes in both jigs. Turn over the boards and place a T-bolt into each hole. With the T-bolts positioned with the teeth side down, hammer them to lock them into place in the holes.

• 5

  Turn over the boards to their original position. For every T-bolt, screw in a threaded steel rod. Make sure that all rods are perpendicular to the board. Any rods that are out of position can simply be bent back into place.

Building the Chair

• 6

  Use a table saw to slice each section of plywood into two portions. Once cut, the portions should measure 21 inches wide by 4 feet in length. Make certain that the direction of the wood bend is set perpendicular to the saw at an angle of 90 degrees.

• 7

  Position the pairs of plywood pieces face-to-face with one another. Place them in the jigs amid the steel rod uprights for a test fit. Between the rods, the plywood pieces should be firmly pressed to each other without any kinks. If needed, make adjustments to the jigs.

• 8

  Take out the wood from the jigs. Crease in half the two sections of plastic sheeting and place them into the jigs with the folded side down.

• 9

  Use the 2-part epoxy per the manufacturer's instructions to cover the face of one of the boards of plywood.

• 10

  Use a paint roller and cover one side from one piece of each pair of plywood sections. As before, press together a pair of plywood pieces, then place it in the chair jig. Be sure the plastic lays between the plywood and the jig. Repeat the process for the other two pieces, placing them into the base jig. While the ends of the outside pieces of the curve will be slightly shorter then the pieces on the inside, the ends need to be as flush as possible. Let the epoxy cure completely as per the directions from the manufacturer.

• 11

  Take out the bent plywood from the jigs and use a table saw to trim the ends so they are flush.

• 12

  Take off the plastic from the jigs. Place the sheeting on the floor. On top of the plastic sheeting, position the pieces of bent plywood on their sides.

• 13

  Make use of a paint tray and fresh roller to mix the 2-part epoxy. Use a paint roller to apply the epoxy and coat each side of the pieces of bent plywood. Make sure the epoxy cures fully.

• 14

  Use sandpaper to remove any abnormalities on the wood portions. Position the base so the open end of the "U" is flat on the floor. Position the chair on the base's flat portion so that it is stable.

• 15

  Use a drill to put four 3/8-inch holes into the seat section residing over the flat part of the chair's base. A three inch square configuration will be formed by the holes. Run the carriage bolts through the holes to attach the base to the chair. On the underside of the base, put on a washer and nut on each bolt and firmly tighten.

• 16

  Permit the epoxy to dry and reach its full strength. Once everything has fully dried, the chair can be used.