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How to Make a Folding Chair
Materials and Tools:
- outdoor fabric
- (7) 2x2 pressure-treated baluster with mitered ends
- straightedge
- drill
- wood glue
- tape measure
- 2-1/2" wood screws
- speed square
- staple gun
- 1/2" staples
- 1/8" drill bit
- 1/4" drill bit
- pencil
- (2) 3" x 1/4" bolts
- (4) 1/4" washers
- (2) 1/4" nuts
- wood filler
- exterior paint
- miter box and saw
Cut Balusters
Measure from the outside edge of the mitered end and mark with a pencil at 25" on four balusters. Draw a straight line on the 25" marks using a speed square and pencil. Cut all four balusters using a miter box and saw to create the chair legs.
Cut and Dry Fit Cross Braces
Measure, mark and cut two pieces at 10", two pieces at 12-1/2" and two pieces at 14". Dry fit the pieces by placing the two 12-1/2" cross braces between two of the legs. Next, place the two 10" cross braces between two of the legs. Then, place the 14" braces at the square end of the legs. Measure 3" from the mitered end of each leg, and make a mark with a pencil.
Attach Legs to Braces
Align the bottom cross braces on the 3" mark, and pre-drill a hole through the leg and into the brace with a 1/8" drill bit. Apply wood glue to each end of the cross brace, and attach the legs using wood screws. Align the top cross braces flush with the square end of the legs, and repeat steps. Fill holes with wood filler.
Create 'X' Pattern
Measure 12" from the square end of each leg, and mark with a pencil. Use a speed square to mark the center of the leg at each 12" mark. Drill a hole in each leg on the mark using a 1/4" drill bit. Slide washers on each bolt end, and attach the legs together in an 'X' pattern with the bolts. Secure with nuts.
Sand and Paint
Sand the piece using a 220-grit sanding block. Paint all pieces using exterior paint, and allow to dry according to label instructions.
Make Fabric Seat
Fold fabric, and wrap one 14" baluster. Secure with staples. Measure and draw a line on the fabric at 18" with a straightedge and pencil. Place the second 14" baluster on the line, and wrap the fabric around the baluster. Secure with staples. Cut off excess fabric with scissors.
Attach Seat
Pre-drill holes in the top cross-braces using a 1/8" drill bit. Place the fabric wrapped balusters on top of the base with the staples facing down. Secure the pieces together driving wood screws through the pre-drilled holes on the underside.
