Make a deck chair

Instructions are given for an adult's and a child's deck chair. Materials and measurements for the adult chair are given first; any changes for the child's chair are written in brackets. If there is only one figure, it applies to both sizes.

You need:

• Cutting and Assembly diagrams (Download PDF file, requires free Adobe Acrobat Reader)
  
• Four (three) 8-foot lengths of 2- x 1-inch clear hardwood, such as birch or maple
  
• Four slip washers
  
• Four 3/8-inch lock washers
  
• Four 5/16-inch carriage bolts, 1-1/2-inches long, with four corresponding nuts
  
• Ten 1-1/2-inch wood screws
  
• Saw
  
• Hammer
  
• Chisel
  
• Plane
  
• Drill with assorted bits
  
• Screwdriver
  
• Pliers
  
• Set square
  
• Tape measure
  
• Sandpaper in various grades
  
• Varnish or wax
  
• Piece of sturdy fabric such as canvas, duck or denim OR drapery chintz fused to both sides of sturdy fabric with Stitch Witchery or similar bonding web, 52- x 18-inches (40-3/4- x 12-1/2-inches)
  
• Matching thread

To make:

1. Fabric seat: Press under 1/4-inch, then 1/4-inch again, along long edges of fabric. Edgestitch along both folds. Press under 1/2-inch, then 2-3/4-inches, along short edges to form sleeves for wood. Edgestitch along first fold then 1/4-inch from this. Machine-zigzag ends of stitching lines to reinforce.

2. Mark and cut wood as follows:


• A - 2 pieces 22-inches (16-1/2-inches) long
  
• B - 2 pieces 48-inches (36-inches) long
  
• C - 2 pieces 18-inches (13-1/2-inches) long
  
• D - 1 piece 23-1/2-inches (18-inches) long
  
• E - 2 pieces 33-inches (24-3/4-inches) long
  
• F - 2 pieces 20-1/2-inches (15-inches) long

  With pencil, label each piece.

  3. Cut notches, 3/8-inch deep, in A, D and F, as shown in Cutting Diagram (cut sides of notch with saw, then chisel out flat bottom). Cut check-mark shaped grooves, 3/4-inch deep, in E pieces, as shown in Cutting Diagram. With plane, round off one long, unnotched (top) edge on one A piece and one F piece. Sand all pieces smooth. Wax or varnish as desired.

  4. With a 3/8-inch bit, drill holes for bolts, right through and at right angles to broad sides of B, C and E, in positions shown in Assembly Diagram. With a larger bit, countersink appropriate side of each hole to accommodate bolt heads and nuts.

  5. Slip rounded A piece through sleeve at top of fabric seat, having round edge facing up at top. Slip rounded F piece through sleeve at bottom of fabric seat, having round edge facing up at bottom.

  6. On a flat surface, assemble pieces E and F into a rectangle, fitting notches in place as shown in Assembly Diagram. Drill holes (to fit screws), 1-1/2-inches deep through top ends of F pieces centred over notches. With a larger bit, countersink holes to accommodate screw heads. Screw together. (Note: It is important that each assembled unit lies flat, or finished chair frame will be warped. If unit does not lie flat, adjust tightness of screws to correct tension). Assemble pieces A and B into a rectangle, fitting notches in place as shown in Assembly Diagram, being careful that fabric is not twisted and that rounded A piece is in correct position. Drill holes (to fit screws), 1-1/2-inches deep through top ends of A pieces, centred over notches. Countersink holes as before. Screw together. Assemble pieces C and piece D into a U-shape, fitting notches in place as shown in Assembly Diagram. Drill holes (to fit screws), 1-1/2-inches deep through top ends of piece D centred over notches. Countersink as before. Screw together.

  7. Bolt units together as shown in Assembly Diagram detail, leaving bolted joints slightly loose so chair may be folded up.