Spring has finally arrived and that means more daylight and warmer weather! I couldn’t think of a better way to welcome the season than with an outdoor DIY.  Just imagine it’s a beautiful Spring morning and you step outside to have your morning coffee in a beautiful patio chair you made… YOURSELF! Well, I’m here to make that a reality for you with this DIY Patio Chair tutorial.

While searching for inspiration, I loved this patio chair style I’ve seen at both West Elm and Restoration Hardware. Its low, boxy shape and wide seat cushion make it perfect for putting up your feet and getting comfortable. The price to buy new patio chairs like these was quite expensive so I was determined to design my own for an affordable price.

I was definitely a novice when it came to woodworking as this was the first wood project I’d done that required so much planning. BUT I live by — anything is possible if you just try!! I’ll have all the tools, supplies and measurements you’ll need to make this DIY project as easy and comprehensible as possible. YOU GOT THIS!

LET’S GET STARTED

Here is all you’ll need to make ONE chair. Make sure to double the number of materials needed if you want to make a set of chairs.

BUILDING THE CHAIR FRAME

STEP 1 – Cutting wood

Taking a measuring tape and circular saw – cut all the wood pieces for the chair frame to size. (Keep a saw handy as we will need it to cut chair bottom and backrest pieces later on)

• 2 pieces of 2×4 wood – CUT AT 30.5”
• 4 pieces of 2×4 wood – CUT AT 27.5”
• 3 pieces of 2×4 wood – CUT AT 24.5”
• 4 pieces of 2×4 wood – CUT AT 20.5”
• 2 pieces of 2×2 wood – CUT AT 27.5”

STEP 2 – Drill pocket holes

All the 27.5” and 24.5” pieces we just cut need pocket holes so that we can assemble the chair together.

• 4 pieces of 2×4 @ 27.5” – NEED 4 POCKET HOLES (all on one side – 2 at each end)
• 3 pieces of 2×4 @ 24.5” – NEED 4 POCKET HOLES (all on one side – 2 at each end)
• 2 pieces of 2×2 @ 27.5” – NEED 2 POCKET HOLES (all on one side – 1 at each end)

For the (4) 2×4 pieces of wood use a drill (drill bits) and pocket hole maker and drill down on A and C on the pocket hole jig. This will create 2 evenly spaced pocket holes.

Next, take the (2) 2×2 pieces and drill one pocket hole at each end on the B setting. Since this is a smaller piece of wood we only need 1 hole at each end.

Tip: Make sure the pocket holes are made at each end on the same side of the wood.

STEP 3 – Lay out the pieces

I like to lay out the pieces before I drill— just to make sure everything was measured and cut correctly! Here are the pieces you’re going to need for ONE side of the frame from top to bottom:

(1) 2×4 at 30.5” – Arm rest

(2) 2×4 at 20.5” – Sides

(1) 2×4 at 27.5” – Center piece (pocket hole facing in where the cushion will be)

(1) 2×4 at 27.5” – Bottom piece (pocket hole facing down) Note: I have it the wrong way in the photo below. the holes should face down so you never see them once the chair is completed

(1) 2×2 at 27.5” – Extra support for the arm rest and sides (pocket holes facing down)

STEP 4 – Build the frames

Here is a list of all of the hardware needed to attach the pieces together.

First, attach the armrest (30.5” – 2×4) to the (27.5” – 2×2) brace using (3) 2.5” construction screws. Make sure the 2×2 piece is centered both width and lengthwise on the armrest piece. Drill the construction screws through the 2×2 into the 2×4 to attach it. No exact measurement needed just evenly spaces between the pocket holes.

Next, attach bottom and the middle piece (27.5” 2x4s) to the side piece (20.5” 2×4) with 2.5” pocket hole screws. The middle 2×4 is part of the seat and is positioned 8.5” up from the bottom.

Next, do the same thing to the other “side piece” (20.5” 2×4), and use pocket holes to attached the arm rest brace as well to complete the frame

STEP 5 – Attach the left and right frames together

Once both side frames are complete, it’s time to attach them together using the (3) 2x4s at 24.5” with pocket holes facing down and in.

Two of the pieces will be used to complete the seat frame (8.5” up from the bottom) at the front and back.(pocket holes facing into the square so its covered with the cushion) The third piece positioned at the TOP / BACK to create a continuous flat “U” shape around the top of the chair.

The chair frame is complete! YAY!

ADDING THE SEAT BOTTOM

STEP 6 – Cut the wood

Next, cut the wood pieces to make the seat bottom.

• 2 pieces of 2×2 wood – CUT AT 21.5”
• 6 pieces of 1×2 wood – CUT AT 24”

STEP 7 – Assemble

Locate the front of the chair and then the middle seat 2x4s that are 8.5” from the bottom. The 2×2 pieces of wood will be positioned inside the seat 2x4s — 3/4” down from the top edge of the 2×4 and shoved all the way to the front of the chair. This will create an empty space at the back of the 2×2 piece. To attached use 2.5” construction screws and drill through the 2×2 into the 2x4s to attached. No exact measurement for this just evenly spaced and secure.

Next, take the (6) 1×2’s and hammer them into the 2×2’s with 1.5” brad nails. Simply evenly space them along the 2×2 piece of wood. This will be where the seat cushion sits.

NOTE: Leave 3/4” space at the back of the 2×2 to attach the backrest.

MAKE THE BACKREST

STEP 8 – Cut the wood

Here’s the wood and measurements needed to make the backrest.

• 4 pieces of 2×3 wood – CUT TO 19.5”
• 2 pieces of 2×3 wood – CUT TO 18.25”

STEP 9 – Drill pocket holes & Assemble

First, drill pocket holes on all 4 of the 2×3’s. Next, layout the backrest design – one 18.25” on each side and four 19.5” across the middle with pocket holes facing up. Using pocket hole screws attached the 4 middle pieces to the two side pieces. For a clean finish, cover the pocket holes using wood glue and pocket hole plugs and give those areas a good sanding!

Finally, attach the backrest to the chair. I also wanted the backrest to slant back for a more relaxed feel. Sit the backrest on the remaining 3/4” space at the back of the 2×2 piece of wood at the back of the seat AND then lean it back to the back frame. Using 2 1/2” construction screws, drill up from the bottom of the 2×2 into the backrest to attached. (pictured below)

STEP 10 – Stain

Prep the chair before staining it by using a stainable wood filler anywhere you see imperfections or gaps. I used an exterior stain by Valspar in the color Canyon Brown and I absolutely love the finish. It was the perfect wood tone I was looking for.

STEP 11 – Add cushions

All the measurements for the chair are based on the cushions that I bought at Walmart. They were the perfect size and depth but they didn’t have them in the color that I wanted. So I used the cover as a pattern and made my own cushion covers! For an in-depth tutorial on how to make the cushions, watch the entire YouTube video here!

This DIY was so much fun and I hope I’ve inspired you to make your own patio chairs this spring. Watch the video below to see my build them and comment if you have any questions!

CREDIT: https://www.xomacenna.com/blog/diy-patio-chairs