Intro: Capsule Chair
This is a chair that i recently constructed for a project, It is not exceptionally difficult to make. However it did take me some time.
What you will need:
Three inch screws
Optional: Jig kit
Create a template, this is not completely necessary, however I found it much easier to cut out the design that i wanted to cut the wood into once i created a plywood template. The template was made up of four pieces of plywood that came together into a type of crescent shape.
Cut all of your 2x8s in half so you have two sets of 7 lined up in a square like formation. If you created a template now is the time to use it, if not begin to sketch the crescent like shape on the wood. To cut the wood, I suggest a jig saw.
It is time to secure all of your side pieces together. to accomplish this, two things were used. the first, wood glue, the second a jig. I did not have a jig set so I just made one. I began by gluing the top two, the bottom two and the middle three. For each glued set I then used the jig and screws to secure them together more. For each set, i used two screws. When It came time to secure all of the sets together, I began with the top two, saving the bottom set for later. Then repeat the necessary steps to create a second identical side piece, yet again leaving the bottom set, the set that will attach to the base, for later.
Now we need to create the base. you will need 2, 24 inch pieces and 2 21 inch pieces, or in other words one 2x4 cut into four pieces. To get the shape I needed on both curved base pieces, I placed one 24 inch piece down and the bottom set of the side on top of it so I could outline the bottom set onto the soon to be base piece. I then used the sander make the fit between pieces as clean as possible. Then you will want to repeat this on for the other side of the base. After both base sides are completed, use your two 21 inch pieces to secure the 24 inch pieces together, by gluing or screwing.
Once you have your base completed and sanded to fit its counter part on the crescent like side, finish securing your side together, by both gluing or screwing.
Place your completed base on the ground, take one side and place it on the base. use a wall or table so that your side and the ground are perpendicular. Take a 24 inch piece of 2x4 and screw it to the the furthest point front on the top of one side, preferably the side being supported on the wall. after the 24 inch piece is secured to one side, place the other (non secured) side on its side of the base, and then proceed to screw the other half of the 24 inch piece to the other side that does not yet have anything holding it up. Next take four clamps and place each where the base connects to the sides. The sides will be glued to the base at a later point.
Now cut your 2x4s into 24 inch peices, and begin to place the peices along the backs of the sides
once you finish layering the back of the sides, you may need two other people to pick up the shell of the chair. once the chair is picked up, line glue along the base and set the shell onto the base again and wait for it to dry.
Now you will need to cut your remaining 2x4 pieces to 21 inches to create the chair on the inside. Sketch the basic design onto the inside of the wood, I suggest a base of around 16 in, with a height of 17 in. using the correctly sized drill bit for the screws you are using, drill out holes along the sketch you made of the chair, space the holes so that there are two for each 3.5 inches. Now how you secure the wood is up to you, my wood fit nicely so i was able to keep the chair up right and just hold the wood while I screwed it in, or if needed, you could set the chair onto its side to keep the wood in place better while you secure the 2x4 pieces.