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How to make a Kentucky Stick Chair

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wooden stick chair
Stick chair project

Dimensions given throughout this project are in both imperial (inches) and metric (mm). The imperial measurements are given first, followed by the metric measurements in brackets ( ).

Wood size (width and thickness) and alternative sizes

The stock size used in this project is 1½" x 1¼" (45mm x 33mm). This is not a common size in a lot of places.
If you cannot obtain this stock size or anything close, then you can rip (cut lengthwise) an acceptable size from a wider stock. For example, you could rip three equal size pieces out of 2" x 4" (100mm x 50mm) stock.
The size (width and thickness) of the stock that you use does not have to be exactly the same size as the stock size used in this project, as long as it is within a bull's roar and all the pieces are uniform.

What you will need

You will need 54ft (16.5m) of 1½" x 1¼" (45mm x 33mm) wood.
If you cannot source the stock size, read the above paragraph.

You will need 4 pieces of approximately 5/32" (4mm) diameter galvanized mild steel wire - 32" (800mm) long.
You will also need 16 galvanized wire staples 1" (25mm) long.

The wire size mentioned above is the approximate size (for rounding off purposes) of 6 gauge AWG (American Wire Gauge), which is the same as 8 gauge British SWG (Standard Wire Gauge), also referred to as number 8 wire (NZ).

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The cutting list

Note: If you cannot obtain the exact stock size as listed in the cutting list below, refer to the paragraph 'Wood size (width and thickness) and alternative sizes' on the previous page.

ITEM ID DESCRIPTION STOCK SIZE LENGTH HOW MANY PIECES
[a] seat 1½" x 1¼" (45mm x 33mm) 15" (375mm) 6
[b] seat/back legs 1½" x 1¼" (45mm x 33mm) 35" (875mm) 2
[c] back longer 1½" x 1¼" (45mm x 33mm) 31½" (787mm) 4
[d] back shorter 1½" x 1¼" (45mm x 33mm) 29¾" (745mm) 2
[e] back/front legs 1½" x 1¼" (45mm x 33mm) 42" (1050mm) 2
[f] couplers 1½" x 1¼" (45mm x 33mm) 9⅛" (228mm) 9
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