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1. Make the templates
Make a template for the curved shapes A, B, C and D by drawing onto cardboard, scrap plywood or 4mm MDF. Use a 25mm grid pattern (see Diagram 2) or draw the grid onto the board then create the shapes. Cut out with a jigsaw or bandsaw.
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2. Cut the curves
Cut parts A, B, C and D with a sliding compound mitre saw or circular saw. Use the templates to transfer the shapes to parts A, B, C and D, then cut out with a jigsaw. Sand curves and edges using 100-grit abrasive paper. |
3. Make the base
Cut seat slats and round over top edges with a 5mm radius router bit. Position the base supports parallel to each other, with the middle support centred at 550mm. Fix the first and last seat slat with a 50mm x 8g stainless-steel decking screw at each support (see Diagram 1). Pre-drill clearance holes and keep the last slat 60mm in from the back edge of A. Use exterior PVA glue on joints between slats and supports. Equally space the other slats and screw-fix.
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4. Attach the back supports
The three back supports sit at 115ยบ to the base. Clamp the lower end of each to the back of part A. The outer back supports are located on the inside of the seat supports, the centre one can be either side. Drill a 10mm-diameter hole in the centre and loosely fix with 75 x 10mm galvanised cup-head bolts. |
5. Add the top rail
Mark out the top rail E (see Diagram 3). Cut out scalloped shape with a jigsaw and round edges. Position and clamp the top rail 40mm above the back supports. Pre-drill and fix in position with two 50mm x 8g stainless steel decking screws through the top rail into the back supports. Add exterior PVA glue to the joints.
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6. Attach the armrest
Position armrest C, 220mm down from the top of the back support. Drill an 8mm-diameter hole in the centre of the armrest and back support and loosely join with 100 x 8mm eyebolts. Position armrest support D 80mm from the front of A and attach with an eyebolt. Position support D against the armrest and fix with glue and three 65mm x 10g stainless steel screws from above. Tighten eyebolts and repeat other end. |
7. Attach the back slats
Cut back slats and round over the edges using a router. Position bottom slat 100mm above the lower end of the back supports. The third slat from the top is cut to fit inside the armrests. Equally space remaining slats and fasten to back supports with a 50mm x 8g stainless steel decking screw at fixing points.
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8. To finish
Sand all surfaces. Tighten the bolts and eyebolts at the angles shown, to go with the pull of the chair. Apply two coats paint. |
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