This is a chair born out of necessity. Well, not really. It just sounded cool. It is quite comfortable though. In fact, I am sitting in it now. But I digress. I got all of the wood I used from the Sears store in my city. So the only things I bought were the two bolts and nuts. Overall, this project cost me 20 cents. Not bad.. It folds too for easy storage.
Step 1: Materials & Tools
You will need:
4-40" 1x1.75 Boards
2-78" .75x3.5 Boards
I know these are strange messurements, but I did get these boards from pallets. You can use many different sized boards but these worked well for me.
Step 2: Cut the Supports
Cut two of the 40" boards down to 32"
Step 3: Mark the Angles
Lay out your your boards to the angle that you will want your chair to be at. Mark the angle; you will need it later. Lay a board across the bottom. This will help the find the angle that your chair will set at.
MAKE SURE THE 40" ONE IS ON THE OUTSIDE OF EACH SIDE!
Step 4: Cut the Foot Angles
One of the feet happend to be 45 degrees, which was nice. The other one was tricky because the angle was greater than the saw could do. So I propped it up with a two by four and braced it with a wedge of wood and pushed on the propped up part. Next lay the newly cut wood up against another board to make sure the angles match up.
Mark the center by connecting the corners of the x. Drill a 1/4 hole at the mark. Countersink so the bolt is flush..
Step 6: The Back
Cut 18" slats out of the remailning boards. Check by standing up the boards where they will go on the BACKSIDE of the back. If it is not on the back, it will not fold properly. Be sure to mark their locations, because it will make the next step easier.
The bottom slat determines the angle of your seat, so be sure it is in the right spot!!
Step 7: Glueing (Gluing?)(Glooing?) and Nailing
Line up the back-boards with their marks. Drill two 1/16" holes per side per board. Add wood glue and hammer in finishing nails.
Step 8: The Buttrest
Or the seat. Which ever you prefer. You will want to subtract the width of your side supports (mine were 1") times 2 from 18" and cut that many inches out. For example since my side supports were 1" wide each, I made my seat-boards 16" long. Repeat the attaching process from the last step. I added another nail in though. Put the bolts in when you are finished that.
Step 9: Sand Like You Have Never Sanded Before!
Since this is recycled wood, it will be in pretty rough shape. To combat that, I sanded the mess out of my seat. I used a dremel multimax with the sanding attachment. You could use regular sandpaper, but that would take ages. I like to leave a little bit of the stamps and such because it gives it a cool look. Especially for my "man cave."
Step 10: Sit Back and Enjoy!
Now you can finally sit back and appreciate your fine work. Adding pads for outdoor chairs increases the comfort by the way. Enjoy!