Step 4: Finish Up

15. Drill a total of twelve 1/8” diameter holes through the chair frame from top-to-bottom, again taking care to align them as straight as possible. The holes should be centered on the rows of holes in the MDF, the two edge rows and the center row.

16. Drill a matching set of 1/8” diameter holes through the pieces of plywood.

17. Take piece number one, the bottom of the seat pan, and attach it to the underside of the seat piece of MDF with glue and stainless steel screws. It should be aligned so that all the holes in the two pieces are centered on one another, allowing for a 1/4” overhang of the MDF on each end front-to-back, and 3/4” of an overhang side-to-side, which overlaps the steel frame.

18. Do the same with piece number three, the back of the back cushion.

19. Insert a tennis ball into all fifty holes. They are available used, quite cheap, on eBay. If you have done everything right so far, all of the balls should fit snugly and none should push through.

20. Fit piece number two over the balls in the seat pan. Again, everything should fit snugly, trapping the balls in between two retaining edges created by the plywood. Glue and screw into place.

21. Do the same with piece number four, the front of the back cushion.

22. Now use twelve 1/8” diameter machine screws with washers to go through the holes drilled in step 15 from top-to-bottom through the frame and both pieces of plywood. Tighten nuts and washers on the underside, snug against the frame. Use a Dremel or angle grinders to trim any excess screw length down flush with the nut.

23. Cut four strips of plywood that are 3/4” by 16-1/4”. Sand, stain, and seal as desired. Glue on the four remaining exposed edges of MDF.

24. Sit down and take a well-deserved rest.

The first picture shows the first three pieces in place. The next couple are close-ups of some of the joints, and alternate views of the chair. The last photos, the black version, is the prototype I made where the balls did not contour. It used masonite instead of plywood, and an external bracing system instead of the internal MDF substrate.

any issues with tennis balls wedged in you butt crack after prolonged use?
love the idea
Some new schools I've seen dont even have a wood shop class.
My old dog would've gone nuts over this...
<a href="http://darkxblog.ru/" rel="nofollow">Все о строительстве</a>
imagine gluing a ton (almost literally) of tennis balls together in hexagon patterns and having a chair that is comprised entirely of tennis balls. It would probably be pretty comfy too.
Hey I found this on google images... if this inspires you
lol send me a link please!
thanks! I'd completely forgotten about this idea!<br>
OMG you just gave me a great idea!!! if i do end up doing that i'll post an I'ble of it (and of course i'll give you credit :) )
ha me and my gifted class are gonna make this. any tips?
cool<a href="http://www.cinemaobzor.ru/" rel="nofollow">.</a>
This is very cool!
You can go to your local tennis arena/gym(?) and pick some up in the throw-away-your-old-tennis-balls basket. They're there for recycling so if you use them for something-- it's all good!
Scenario: Tell you're girlfriend to sit in it, when she does say ::sarcastic::"Hey! you're sitting on my balls!"::/sarcastic:: I was also thinking, instead of using two sheets of MDF put some form of mesh/fabric as backing so the balls actually conform to you're body's shape and distribute the weight. Kinda like a trampoline effect but the mesh acts as a firm buffer where the balls act like a soft buffer.
I like that idea... There's some pretty strong mesh materials on the market, nowdays.
thats AWESOME!
Great work!
What you need is a &quot;Do not fart&quot; sign to go with it, or keep a tennis racket handy :-)
okay is this chair comfortable
Almost looks painful to sit on........<br />
oooooooooo I like the black with the tennis balls =D<br />
na you just like balls<br />
im joking<br /> <br />
who's your model??? now that's a hot project!
she looks bored lol
I expected her to look far more excited about sitting in a chair.
Hahahaha<br />
Fun idea, but looks unconfortable.
It might sell to the kinky crowd. :D
Thats not me :-(
Not you in the chair or your not kinky? We can work on at least one of those. :)
Me. And you will have to find me before you un-kink me.
Un-kink? Why would I want to do that? :P
You said we could work on one of those...
I wasn't talking about un-kinking. I was talking about adding some kink. Haha
I'm all for extra added kink, though I'm sure a tennis ball chair never before surfaced in the list of ideas.
For the sports crowd ;) I'm a baseball girl myself but to be honest, neither of those choices are the balls I'm into HAHA
Actually, now, I have an AC/DC song stuck in my head... :)
Plus baseballs are hard and I'm guessing you'd want 'em a little softer.
Oh... <sub>my bad</sub><br/>
Awesome! Can't believe I didn't see it yet.
I'm reminded of the seat covers of beads cab drivers used to swear by. this idea is really a mind bender.
Still do swear by in China.
How many passes on the cutter did that take? This is awesome, good job.
looks cool wish i could try it
this seems nice,I oughtta make one

About This Instructable


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Bio: Furniture hacker. Author of Guerilla Furniture Design, out now. Find me on Twitter and Instagram @objectguerilla.
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