I decided to make this chair from a broken 1950's lawn chair. The lawn chair legs were fatigued and bent. Once I had it apart, I was able to save the seat and back. I searched for different style chairs that would allow me to use the salvaged pieces. I chose this style from Ana White's collaboration with Home Depot. You can view those plans here:
Step 1: Safety,Tools and Materials
I wore safety glasses and hearing protection whenever I used power tools. Also, I used gloves while operating the Angle Grinder.
3 - 8' 2x4s
1 - 8' 2x2
2 - 4" scrap 1x2 pieces
2 1/2" Wood screws
1" Wood screws
6d finish nails
Step 2: Disassembling the Lawn Chair
The bolts were too frozen and rusted to unscrew, so I ground the heads off the bolts using the angle grinder and used a hammer and punch to drive the bolts out. I then used the drill with a wire brush attachment to clean off any rust and loose paint.
Step 3: Cutting the Wood and Altering the Plan
I cut the pieces to the plan's angles and lengths. But realized that they had to be adjusted for the length and width to accommodate the lawn chair pieces. I also had to lower the seat height. The original wood seat plan had an angle change on the seat itself by using individual boards. The steel seat I was working with had to stay on one plane.
Step 4: Frame Assembly and Priming
I used wood glue and 2 1/2" inch screws to connect all the 2x4s and 2x2s to each other.
After filling the screw holes with wood filler and sanding, I primed each piece with 2 coats of Bull Eyes2 primer and sealer. I then applied 2 coats of Sherwin Williams "Ibis White" to the frame. The seat and back had 2 coats of Sherwin Williams "Grounded" brushed on.
Step 5: Attaching the Seat and Back
After dry fitting and adjusting the back angle, 1 inch screws were used to attach the seat and back to the legs and arms. The two pieces themselves attach with 3 small bolts. I used stainless bolts, nuts, and washers. These and the 3 - 2x4s were the only things that I had to purchase. Everything else was left over from other projects. Total cost was under $15.00 dollars.
Step 6: Arm Brace
I added the arm brace for a decorative look to cover the end of the 2x2. It really isn't needed for support because the way the 2x2 is attached to the 2x4 legs gives it enough support.
Step 7: Final Look
Rather than throwing away or recycling the lawn chair, I tried to save it and create a unique chair.
Here are some different views. I hope you enjoyed it.
Thank you for looking.