Step 1: Supplies + Tools
4'x 8' Sheet of 1/2” Thick PlywoodAvailable at Home Depot
There are a lot of different types of plywood. I used ¼” plywood which is strong enough to hold my weight but might not stand the test of time. 3/8” or ½” thick plywood would provide superior durability. I had the plywood cut into strips at Home Depot
.Zip TiesAvailable at Home Depot
Zip ties – also called cable ties or tie wraps – come in a variety of different sizes. I tried both large 10” ties and thinner 4” ties. The thinner ties are much easier to work with.RYOBI 18 Volt Cordless DrillAvailable at Home DepotRYOBI 18 Volt Circular SawAvailable at Home DepotHusky 7" Diagonal PliersAvailable at Home DepotHusky 8" Long Nose PliersAvailable at Home DepotBox CutterAvailable at Home Depot
Step 2: Measure and Mark the Plywood Strips
Measure and mark the plywood with a pencil.
Step 3: Cut the Pieces
I used my RYOBI 18 Volt Circular Saw
with a plywood blade to make the cuts. The laser guide makes it really easy to follow the lines. If you don’t have a laser then clamp a guide to the plywood.
Step 4: Sand the Edges
Smooth the edges with 120-220 grit sandpaper.
Step 5: Mark the Holes
I measured a line 1/2” from the edges and marked an X every 1" inch down the line to indicate drill marks.
Step 6: Drill the Holes
I clamped 2 to 3 boards together to drill the holes on multiple pieces at the same time.
Step 7: Loosely Stitch the Boards Together
I zipped a series of loops into the drilled holes in the first piece. Then I strung zip ties through the holes in the second piece and the zip tie loops in the first piece. This creates a zip tie to zip tie connection/link. Keep the links loose for now.
Step 8: Shape and Tighten
Shaping and tightening the zip ties is an incremental process that requires a bit of patience. The good news is that you can always cut and redo zip ties if you make a mistake. Use long nose pliers to tighten the ties and diagonal pliers to cut the long ends.
Step 9: Add Supports
Method A: I used giant, 3 foot zip ties to make tension supports for the chair. Simply drilling two holes through the plywood and using a box cutter to carve out the area between the holes, I was able to create a rectangular hole large enough to strap part of the zip tie through. I then cut the head off of a second tie to cap the other end. I used the same method to make vertical supports that keep the back from reclining too far.
Method B: For the second chair, I cut some scrap plywood into supports and zip tied them to both the leg and back pieces of the chair.
Step 10: Done!
Good luck making your own ZipStich Chair
and please email or tweet photos to @benuyeda
. For more detailed instructions, dimensioned drawings and different variations of the project, check out our soon-to-be-released book.