This is a chair design by my Grandfather. They are very comfy and can be made without fancy tools.

Step 1: Supplies

Tools:

- Circular Saw

- Drill

- 1/8 and 9/64 drill bit

- Phillips, and sq2 bit

- Clamps

- Saw Horses (or a Workbench)

- Tape Measure

- Square

- Pen

- Hand Plane (optional).

Supplies:

- Outdoor Wood Glue

- 2 1/2" Deck Screws

- 2" Drywall Screws

Wood (for 2 chairs):

(1) 2x6x12'

(2) 2x4x8'

(1) 5/4x6x10' or 1x6x10'

(3) 5/4x6x12' or 1x6x12'

Step 2: Plans

Thanks to my Granddad for making these plans :)

Chair directions pdf.pdf
Download

Step 3: Cut List (1 Chair)

2x4:

(2) 24"

(1) 35"

2x6:

(2) 36"

1x6:

(3) 24"

(2) 30"

(4) 36"

By the way this is not me using the saw without shoes... my brother really wanted to help out, but he didn't feel like putting on his shoes.

Step 4: Back Legs

For the Back Legs, we need to cut at an angle. Now using the diagram, mark out the angles on both of the 36" 2x6s. I could try to explain it, but the diagram is much easier to follow. Once it is marked down, cut along the lines you just marked. When beginning the cut, it helps to hold the blade guard open. If they look like the last picture, then you did it right! Congrats!

Step 5: Assembling the Legs

On one of the 2 foot 2x4s decide which end should be the bottom, and measure up 14 inches from the the bottom, and make a mark. Then use a square to mark it on all sides of the board. Then lay this board on top of one of the back legs. Line the 14 inch mark up with the top of the 2x6. By the top of the 2x6 I mean the side that has no angled cuts on it. Then line the side of the 2x4 up flush with the 1 3/4" angle. Now you can pre-drill 3 holes using the 9/64 bit, and add glue, just make sure that you eliminate any tear-out on the back of the holes. Then Drive in 3, 2 1/2" screws. When assembling the other front and back leg, make sure that you put the 2x4 on the other side of the 2x6. Basically you want the 2 front and back leg assemblies to be mirror images of 1 another. Otherwise when you go to put the seat boards on, one of the front legs will get in the way.

Step 6: Adding the Seat Pieces

Before you add the seat pieces, if you used 1x6 instead of 5/4x6 pick one 24" piece, and add a bevel to the front with a hand plane. This makes the chair more comfortable. If you are going to pre-drill holes for this, try stacking all 3 of the 24" pieces so that you can drill all the holes at the same time using the 9/64 bit. Now take the board with the bevel and one of the leg assemblies, and orient the seat piece so that the bevel faces the front. Now using a square make sure that joint is square, and drive in the 2 1/2" screws. Now grab your other leg assembly, and line it up with the other assembly. It helps to use a clamp. Now make sure that everything is nice and square for this step. If you want you can measure the distance between the outer edges of the back legs, and tweak it until the distance is 24". Now you can add the rest of the seat pieces. The spacing between the seat pieces if 1/2". If you've done it right it should look like the last picture.

Step 7: Arm Assembly

Now take one of the 30" 1x6s and the 35" 2x4 and line them up at a right angle. Then glue and screw the 2 pieces together using the 2 inch drywall screws, and the 1/8 drill bit. Now measure over 24" from the inside edge of the 1x6, and make a mark. Now line the other 1x6 with this mark, and square it up. It doesn't matter if the outside edge isn't flush. It's the inside measurement that matters. Now you can glue and screw this joint together. Now for alignment later, measure back 2 inches from the front of the 2 arms and make a mark. You can also pre drill pilot holes with the 9/64 bit within 3.5 inches behind the mark. You're now done with the Arm Assembly.

Step 8: Attaching the Arm Assembly

Now take the Arm Assembly over to the rest of the chair, and if you need, get a helper to hold the back as you line up the front of the 2x4's with the marks you made. Now drive in the 2 1/2" Screws. The chair should be sturdy enough for your helper to let go now. If you are using 1x6, you might want to bevel the arms right now.

Step 9: Adding the Back Slats

Now take your 36" 1x6 pieces and dry fit them into the chair and mark where you need to put the pilot holes and drill them out with the 1/8 bit. Also drill a hole on the bottom of these boards. Now you can begin attaching the boards with 2" screws. Tweak them until they look just right. It's very difficult to get the spacing perfect, so just do your best. And you're done!!! Congrats! Now you have to clean up the mess XD. Well you don't haaaave to but it's a good idea to.