I have already made an activity table for my kids (read that website article here and get the table plans here), but I had put off making the chairs for it until now. The chair is made from 3/4 inch plywood and you can make four chairs OR two chairs and the Kids Activity Table from a single sheet (4'x8') of plywood. Read the chair website article here and get the chair plans here. Continue reading...
Step 1: Tools and Plan
Here is a list of tools that I used in this project. (Amazon Affiliate links help me with no additional cost to you)
Table Saw: http://amzn.to/2kKxX9N
Digital Angle Finder: http://amzn.to/2kKGJo6
90 degree screwdriver: http://amzn.to/2kB1umK
GET THE PLANS HERE: http://www.stoneandsons.net/plans
Step 2: Breakdown the Plywood
Breakdown the plywood according to the plan. In this particular project, we have several small pieces with four legs and two chair back uprights that will need to be tapered.
Step 3: Assemble the Under-the-seat Storage Section
In this step we drill the pocket holes to assemble the bottom pieces together. Then we attach the sides with glue and more pocket holes. This whole assembly will be the "foundation" for the chair. You will end up with a small storage area in the front under the seat and a larger space in the back under the seat. Glue all the joints.
Step 4: Taper and Attach the Legs
In this step, we will taper the legs and attach them to the shelf assembly we just made. First of all, if you have never tapered anything or don't have a tapering jig, I got you covered. Download a FREE plan of a shop made tapering jig here and here's a video explaining how it works.
You will need to measure where your tapers will be and place the work piece in the jig to cut the waste off. The plan will tell you where to measure and mark the line. After securing the work piece in the tapering jig and cut it on the table saw, you can now hold the legs in place where they will be attached and draw a line so you will know where to apply the glue. Next, pre-drill the holes for the screws and attach the legs. One thing to note here is that your seat is level.
Step 5: Attach the Seat
At the bandsaw, cut out the notches needed to fit the seat between the chair uprights. Next, drill pocket holes between the notches to be able to attach the seat to the chair uprights. The rest of the seat will be held in place by glue. Be sure to clamp it.
Step 6: Attach the Last Three Pieces to the Chair Back
The two smaller pieces should be installed before the larger piece. The reason is so that there's room to attach the smaller lower piece as it's held in by pocket screws from the inside. The larger piece gets an angled cut on the bottom portion to match the chair upright. I use a digital angle finder to get the right angle, super helpful (product link in step 1). Use glue on all joints and as a tip, use clamps to help you hold pieces in place while you drive the screws in. *Note: I had to use a 90 degree screwdriver in some instances due to small spaces. If you need a 90 degree screwdriver I've included a product link in step 1. The link I included is not to the one I use, but the one listed should work just fine.
Step 7: Sand and Finish
The last step is to sand away all the splinters, rough edges and soften the corners. It's important that you sand the seat edges real good. Use your favorite finish to dress it up. Send pics my way if you decide to build this chair to firstname.lastname@example.org