I am a total sucker for old wooden chairs. When I saw six of them on the curb waiting for trash pick-up I knew I couldn't let these 1950s-era beauties go to waste. Never mind that my house is already overflowing with chairs, and I was pretty sure my husband would not be as excited about my new chair collection as I was. The key to appeasing the hubster is to simultaneously present my curbside finds along with a spirited description of my upcycling plans.
While I didn't need a bunch of chairs, I did need a a comfy place for people to sit if they were visiting my studio (a converted shed). The space is so small that the piece of furniture needed to be an odd size and visually lightweight. These chairs seemed like a great foundation for creating a seat to meet the needs for my studio. Hubs was pleased. The scrap wood pile was plentiful that day. My other projects had reached a bit of a pause. It was sunny outside. Work began.
Making a couch, sofa, settee, bench, loveseat, or whatever you want to call it using two old chairs is really easy. The tutorial is specific to the chairs I had--with a bit of tweaking, this DIY can be applied to pretty much any two chairs (even if they don't match).
Step 1: Tools and Materials
Sander with sandpaper
Two old chairs, preferably with arms (only need one chair needs to have arms)
1/2 yard fabric
High-density foam large enough to make seat
Scrap wood large enough to make seat
Step 2: Remove Seat and Arms
If your chairs are covered in a layer of nastiness like mine were, give them a quick wipe-down. It will make your hands much less gross moving forward.
Remove the seats of both chairs by locating the screws underneath the seats. I've noticed that most old, solid-wood chairs use flathead screws rather than phillips-head. Keep the screws handy--we will use them to attach the seat later.
After getting the seats taken off, remove the opposite arm of each chair so that if they are placed next to each other there are only arms on the outsides of the chairs . My chairs had arms that were simply screwed onto the chair seats and backs, so removing them was a breeze.
If you have one chair with arms and one without, remove an arm and attach it to the outside of your previously armless chair to create the same functionality.
Step 3: Strip and Finish
If the finish or paint on your chairs is already to your liking, you can skip this step entirely. Otherwise you will need to do whatever it takes to get the old varnish scraped away. The finish on my chairs was flaking off already, so I just ran a sander over the whole thing to get down to bare wood. After sanding, wipe down the chairs with a damp rang to clean off all the sanding dust.
Once your chairs are down to lovely, lovely wood, you can apply a finish. I chose to just rub in wood block oil so that I could keep all the stains and character that had sunk into the wood over the years (plus I had some laying around, so, you know, that made the decision really easy). Apply using a clean cloth and always rub in the direction of the wood grain.
Step 4: Make the Seat
While the oil is penetrating the wood (or stain or whatever), get to work making the seat. Measure one of your old seat cushions front to back and mark a big sharpie line across a scrap piece of wood that is large enough to cover the entire area of the seat. Measure across the back of your chairs and mark your seat depth on the wood with sharpie.
Grab the seat cushion you removed from the chairs. Aligning the seat with your measurements, trace the outside edge of the seat onto your wood with sharpie. Repeat for the other side. Use a jigsaw to cut out the wood for the seat.
After cutting the wood, make sure it fits snugly into the base of the chairs.
Step 5: Cushion, Cushion, Cushion
Place your bench wood on top of a piece of high-density foam. I used 2" so that it would be somewhat cushy. Trace around the edge with a sharpie and cut using a serrated blade. The cutting part sort of sucks--little bits of green foam ended up everywhere. Yuck!
The foam can be pretty expensive--I got it at Joann's and used a 40%-off coupon (which you can always find in their app or online).
Spread out the fabric face-down on the floor and stack your cushion and wooden seat on top. You could iron it if you want to--clearly I didn't bother because I am sort of lazy, and stretching the fabric around the foam seems to take care of the wrinkles.
Fold the fabric over the foam and wood, stapling along the edges. Don't pull the fabric super tight--just enough to squish things together and keep everything in place. Trim off excess fabric.
If your fabric has a pattern with lines like mine does, focus on keeping things straight as you upholster the cushion.
Once the whole seat is covered, flip it over and admire your work. Imagine how lovely you will feel sitting on this soon-to-be-completed bench, sipping some tea and reading on your kindle! Ah, how welcoming this seat will be to your studio guests! Think of all the crap you will inevitably pile onto the spacious seat!
Step 6: Screw It (all Together)
Put your cozy cushion upside-down on a table and position your chairs on top of the bench. Drill pilot holes into the bench by going through the holes on the bottom of the chairs and into the wood of the bench. Using the screws you saved from the old seats, attach the new bench to the chairs. Flip the whole thing over and you are done!