Building Wooden Armchairs

Set an overturned wooden pallet on the floor. Inspect the middle support piece to ensure it is solid because that is a critical piece to chair construction. Replace the pallet if the middle piece is not suitable.

Set a second pallet sideways so the top edge of the frame rests against the narrow side of the support piece below it. Have a helper hold this pallet as you drill 3-inch wood screws through the frame into the support piece every three inches. The pallet on the floor is the first arm, while the pallet standing up is the seat.

Set a third pallet on the floor in the same position as the first pallet. Set up the second pallet onto the third pallet as you did originally. Attach the pallet forming the seat to the third pallet to form the second arm using the same method as before. Have a helper hold the project steady.

Stand the armchair up on the sideways pallets. You should have two arms and a seat. Line up a fourth pallet so the topside is flush against the sides of the other three pallets. This is the back to the chair.

Have your helper hold the last pallet in position as you drill wood screws through the undersides of the pallet’s top boards into the frames of the arms and seat using the same distance between screws as before.

Load an orbital sander with 220-grit sandpaper. Sand down the edges and rough spots on all sides and surfaces of the chair. Dust off the chair with tack cloth. Sand the seat, arms, back and sides again with a 120-grit sandpaper for a smooth finish.

Varnish the entire chair with your desired color of stain. Apply a second coat after the first coat dries to ensure uniformity. Use smooth, steady strokes with a wide bristle brush moving with the wood grain.