How to Make a Lawn Chair

The Seat and Back

• 1

  Place the two 19-inch pieces of 2-by-4 on a flat surface, parallel. They should be resting on the 2-inch edge and approximately 17 inches apart. These are the sides of your seat. Align the 20-inch piece so the cut ends are even with the wide edges of the seat sides. This is your seat front.

• 2

  Apply wood glue to the joints and secure by inserting the 3-inch wood screws from the front of the seat front into the seat sides. There should be two screws on each end of the front-facing board.

• 3

  Position the first of the 20-inch slats (1-by-4 pieces) across the newly formed seat base, so that the front edge of it is 1/2 inch from the edge of the seat front. Secure in place by adding two 2 1/2-inch screws on each end of the slat.

• 4

  Align four more 1-by-4 slats directly behind the one in Step 3, screwing each one down with four wood screws. The back end of the seat sides will still be slightly exposed after the fifth slat is installed.

• 5

  Rest the two 14 1/2-inch boards on a flat surface, resting on their 4-inch sides and approximately 13 inches apart. These are the supports of your back panel.

• 6

  Adjust one of the remaining 20-inch slats (1-by-4) so that the edge is flush with the cut ends of the back support boards and attach with two screws on each end.

• 7

  Add the remaining four slats to the back in the same manner. The last one will overlap by approximately 1 inch.

Arms and Legs

• 8

  Lay two of the 24-inch boards (2-by-4) parallel to each other on the 4-inch sides; they should be 1 foot apart. These will form the legs of the chair and the supports of the arm pieces.

• 9

  Measure 1 inch from each end of a 21-inch arm piece and align those marks with the outer edges of the chair legs. The arm should be on its 2-inch edge so that the widest parts of the legs are perpendicular to the armrest.

• 10

  Secure these pieces together with wood glue and four wood screws. Repeat this process for the other arm/leg assembly.

Putting the Pieces Together

• 11

  Measure along the inside of each leg/arm piece and place a mark 18 inches from the bottom of the legs.

• 12

  Place the seat of the chair between the two leg/arm pieces so that the top is level with the marks from Step 1 and the front of the seat extends approximately 2 inches in front of those legs. You will likely need someone to provide an extra pair of hands during this step to hold pieces in place while you line them up and apply the bar clamps to hold it all together.

• 13

  Mark the center of each leg/arm piece at the seat level. The goal is to find the spot where the middle of the vertical board meets the middle of the horizontal seat side.

• 14

  Drill this spot through both the leg board and the seat support, using the 3 5/8-inch drill bit. Your hole should be just slightly larger than the diameter of the carriage bolt. Insert all four of the 3 1/2-inch carriage bolts and tighten in rounds so that no one bolt is completely tight while others are still loose. Check to make sure they are all secure.

• 15

  Slide the chair back between the arm/leg pieces so that the slightly overhanging slat is at the top of the back support. Align the bottom edge of the back support with the front of the leg boards and tilt the top edge backward to a comfortable angle. You will not be able to angle it further than the back of the leg boards. Use the bar clamps to hold the back in place once you are happy with the angle.

• 16

  Screw the leg boards and back baseboards together in the middle of their connection using the remaining two 2 1/2-inch wood screws.

• 17

  Place a washer on each of the 3 1/2-inch lag screws and screw them through both the leg board and back board. One should be very near the bottom of the back piece (about 1 inch above the seat) on each side, and the other just under the armrest on each side.

Finishing Touches

• 18

  Check your chair for any cracks, dents, or holes and use wood filler to even them out.

• 19

  Sand the entire chair, checking carefully for rough edges or splintered bits of wood.

• 20

  Place the chair upright on a flat surface (such as your patio, deck, or garage floor) and check to make sure all four legs meet the ground evenly. If necessary, trim slightly or sand with a power sander to get even surfaces for a level seat.

• 21

  Paint or stain the chair as desired. If you used treated pine, leave it natural and the wood will gray over time with the weather. If you prefer the natural look without the graying, coat the chair with a weather sealer or weatherproof varnish.