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:

Ana White Chair Plan

Step 1: Safety,Tools and Materials

Safety

I wore safety glasses and hearing protection whenever I used power tools. Also, I used gloves while operating the Angle Grinder.

Tools

Angle Grinder

Miter Saw

Sander

Drill

Hammer

Materials

3 - 8' 2x4s

1 - 8' 2x2

2 - 4" scrap 1x2 pieces

2 1/2" Wood screws

1" Wood screws

6d finish nails

Wood glue

Primer paint

Exterior paints

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.