Table of Contents
- 2Wood and Wood Size
- 3The Plan drawings
- 4Material requirements
- 5Step 1. Commence cutting the frame pieces
- 6Step 2. Cut and make the back top
- 7Step 3: Make the side frames
- 8Step 4. Rebate the back legs
- 9Step 5. Assemble the frame
- 10Step 6. Make the king chair seat
- 11Step 7. Make the king chair base
- 12Step 8. The final touches
Altogether (allowing for a bit of waste) you will need…
25ft (7.6m) of 3″x3″ (75mm x 75mm) wood suitable for exterior use. If you cannot source 3″x3″ (75mm x 75mm) stock, then use 3 1/2″ x 3 1/2″ (90mm x 90mm),
10ft (3m) of 1 1/2″ x 3 1/2″ (90mm x 45mm) wood suitable for exterior use,
14ft (4.2m) of 1″ x 1″ (25mm x 25mm) wood suitable for exterior use,
15ft (4.5m) of 1″ x 6″ (150mm x 25mm) wood suitable for exterior use,
and 9ft (2.7m) of 1/2″ (12mm) diameter dowel (round wood).
You will also need…
56 of 3″ (75mm) wood screws (exterior type),
32 of 1 1/2″ (38mm) wood screws (exterior type),
4 of 3/8″ (10mm) carriage bolts 5″ (130mm) long with nuts and washers,
exterior type wood glue,
And some type of wrought iron or metal pattern for the chair back.
The cutting list
|[a]||back leg||3″ x 3″ (75mmx75mm)||51 1/2″ (1287mm)||2|
|[b]||front leg||3″ x 3″ (75mmx75mm)||29″ (725mm)||2|
|[c]||seat front and rear rail||3″ x 3″ (75mmx75mm)||22″ (559mm)||2|
|[d]||seat side rail||3″ x 3″ (75mmx75mm)||17″ (432mm)||2|
|[e]||angled back piece||3″ x 3″ (75mmx75mm)||15-3/4″ (400mm)||2|
|[f]||horizontal back piece||3″ x 3″ (75mmx75mm)||approx 6″ (150mm) check on job||2|
|[g]||arm||3″ x 3″ (75mmx75mm)||24″ (610mm)||2|
|[h]||front and rear base||1 1/2″ x 3 1/2″ (90mmx45mm)||approx 32″ (800mm) check on job||2|
|[i]||base side||1 1/2″ x 3 1/2″ (90mmx45mm)||approx 26″ (650mm) check on job||2|
|[j]||fillet||1″ x 1″ (25mmx25mm)||measure and cut on site||8|
|[k]||seat board||1″ x 6″ (150mm x25mm)||22″ (559mm)||3|
|[l]||base board||1″ x 6″ (150mm x25mm)||approx 22″ (559mm) check on job||5|
I did not use any fancy joining methods, I simply just glued and screwed. However because of the thickness of the framing wood, I first drilled a 1/2″ (12mm) diameter hole more than halfway into the face piece of wood (where each screw went) and continued all the way through with a smaller hole (screw shank thickness).
Why the 1/2″ (12mm) diameter hole more than halfway into the wood?
It saved using bigger and more costly screws, and although it left 1/2″ (12mm) diameter holes in the wood where every screw went, it was just a matter of plugging the holes with 1/2″ (12mm) dowel.
The end result looked great and was in keeping with the type of chair.
Fix all joints with glue and 3″ (75mm) wood screws, four screws to each joint.
First Drill 1/2″ (12mm) starter holes all but 1 1/4″ (32mm) into each joints face piece.
Then continue through with a smaller (screw shank size) hole.
Add some glue and fasten with the screws.
Finally plug the holes with 1/2″ (12mm) diameter dowel glued in. Cut off any excess and sand.