Build your own outdoor chairs using free plans from Ana-White.com - step by step diagrams, shopping and cut lists, and video tutorial.
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- 4 - 2x4 @ 8 feet long
- 1 - 2x2 @ 20" long
- 50 - 2-1/2" to 3" long - self tapping star bit screws for exterior use
- outdoor appropriate stain
- standard seat cushions (I used these from Lowes)
4 - 2x4 @ 21-1/2" - legs
2 - 2x4 @30-3/8" - arm rests
2 - 2x4 @ 27-1/2" both ends cut at 5 degrees off square, long point to short point measurement, ends ARE parallel
5 - 2x4 @ 20" - or width of seat cushions
2 - 2x4 @ 26" - back - can be modified to match the height of seat back cushion
1 - 2x2 @ 20" - back top - matches the width of the seat cushions
Cut the longest boards first to make sure all the pieces fit on your boards.
For the angle cuts, set miter saw to 5 degrees off square, and cut so the ends are parallel, and the measurement is long point to short point.
Rotate the chair and add the seat slats.
I recommend adding the back slat first, measured out for your seat cushions - 21-1/2" was good for my cushions even though the cushions are 20" - because I was accounting for the back cushion and the depth created by folding the cushion at the back seam.
Once you have the back slat placed, the two center slats are just placed with even spacing (you can eyeball this).
Two screws per joint.
If using a different size cushion, place the cushion in the chair frame now, and measure and cut the back supports to fit your cushions. Remember that a 2x2 that is 1-1/2" wide will be added to the top in the next step.
Position the back rest pieces and attach in three points - to the sides, the back rest and the back slats. These back rest pieces add considerable strength to the chair.