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I’ve been looking for a patio chair set for some time but couldn’t find something within my style (and price, whew – expensive!). And then I came across some inspiration on Pinterest:
- Angela Marie Made’s DIY Outdoor Chair
- House on Longwood Lane’s DIY Modern Outdoor Chairs
- Ashley Thurman’s DIY Modern Outdoor Chair on Build Something
The chair size needs to be built around the cushions so I went on a hunt – and man were they expensive as well! It came down to Big Lots’ Deep Seat & Back Cushion Sets and Lowe’s Arden Selections 2-Piece Deep Seat Patio Chair Cushion.
I ended up choosing the Deep Seat & Back Cushion Set from Big Lots’ simply because it would get here faster. The seat cushion doesn’t have much support so you may want to check out other options or Amazon.
My ideal chair looked (and felt) light and airy. Lucas and I went with the 1×3 option hoping it would give enough stability. I wouldn’t say I trust the chairs completely, but they work for us.
Our hardware store didn’t have any treated options for such small boards so we bought a stain and sealer combination.
If you want something super stable, then go with 2x3s or 2x4s or a combination. Just be aware of the measurement changes.
Materials for ONE Chair
- (72) 1 ¼ inch Pocket Screws
- (22) 2 inch Wood Screws
- (8) 1x3x8 Board
- (1) 2x2x8 Board
- (1) 1x6x10 Board
Equipment
- Pocket Screw Jig (Check out this Kreg Jig)
- Circular Saw/Table Saw/Miter Saw (Check out this Dewalt)
- Clamps (If needed for Pocket Screw Jig)
- Drill & Bits (We love our Kobalt)
Step 1. Cut
The seat cushion I purchased was 24 x 24 x 5’’. You will need to adjust measurements if yours is different.
- (10) 23.5-inch 1x3s
- (6) 24.25-inch 1x3s
- (4) 29.25-inch 1x3s
- (2) 25-inch 1x3s
- (2) 23.5-inch 2x2s
- (4) 24.25-inch 1x6s
Step 2. Sand & Stain
We didn’t stain after cutting on the first chair and it was a nightmare at the end. So take the time now and sand and stain every piece. This also lets you get all of the surface area to prevent water intrusion.
Step 3. Build Arms
The 29.25-inch boards will be the fronts and backs of the arms. Use two of the 23.5-inch boards as the bottom and the two 25-inch boards as the top.
The bottom of the arm nests inside of the front and back while the top sits on them.
Pay attention to the direction your good side of the board is facing. Also, triple check where your pocket holes will be. Look at the picture for better understand of where the pocket screws will go.
Add a 23.5-inch board vertically to the inside of each arm. The top of this board should be 10 inches off of the ground. Pocket screws go on the interior of the chair.
Step 4. Add Front and Back Supports
Use the six 24.25-inch boards for your front and back supports. One will go on the front and five on the back.
Make the lowest one 10 inches off the ground and lined up with the arm support.
The back slats will be spaced with 2.5-inch gaps.
Step 5. Add Seat Support & Slats
Use three of the 2-inch wood screws to attach each 23.5-inch 2×2 to the arm support. Pre-drill a hole and be very careful not to split.
Use another board to determine where to put the 2x2s. You will want your future seat slats to sit flush with the edges.
Add your 24.25-inch 1×6 slats. Pre-drill holes and add two screws on each side of the slat.
Step 6. Add More Arm Boards
This is the point I thought the project would be finished, but we didn’t feel comfortable with the stability. Lucas ran back out so we could add some more boards to the sides. But don’t worry, I already added these cuts to your list.
I decided to lay these horizontally so the pocket holes could be hidden. These horizontal boards will be spaced with 4.25-inch gaps.
Finished!!
Add the cushions and you’ve completed a DIY Modern Patio Chair!
Do you plan on making some chairs soon? Do you have any questions?
Want a FREE DIY Project Checklist & Budget? Click here.