This step by step woodworking project is about outdoor chair made from 2x4s plans. If you want to build a matching outdoor chair for the 2×4 sofa, you should check out these plans. I have designed this chair so you can make it with just 2x4s and screws. You should add nice cushions to make it super comfy. If you have a higher budget, invest in weather resistant lumber. See my other DIY projects HERE.
We recommend you to invest in the best materials you could afford. Therefore, you should buy weather-resistant lumber, such as pine or cedar. Always take accurate measurements before adjusting the size of the components at the proper size. Drill pilot holes trough the components before inserting the wood screws, to prevent the wood from splitting. See all my Premium Plans HERE.
Made from this plan
Outdoor Chair made from 2x4s Plans
Building an outdoor chair
Materials
- A – 2 pieces of 2×4 lumber – 20 1/2″ long, 2 pieces – 30 3/4″ long, 2 pieces – 32 3/4″ long LEGS
- B – 2 pieces of 2×4 lumber – 31 1/4″ long, 2 pieces – 24″ long SUPPORTS
- C – 3 pieces of 2×4 lumber – 24″ long, 5 pieces – 22 1/2″ long SEAT
- D – 2 pieces of 2×4 lumber – 9 7/8″ long, 5 pieces – 20″ long, 1 piece – 31″ long BACKREST
- 7 pieces of 2×4 lumber – 8′
- 100 2 1/2″ screws
- stain, wood filler, wood glue
- outdoor cushions
Tools
- Safety gloves, glasses
- Miter saw, jigsaw
- Chalk line, tape measure, spirit level, carpentry pencil
- Drill machinery and drill bits
Time
- One Weekend
How to build an outdoor chair from 2x4s
Building the side frames
The first step of the project is to build the sides for the outdoor chair. As you can easily notice in the diagram, you need to cut the components at the dimensions shown in the diagram. Drill pilot holes and insert 2 1/2″ screws to assemble everything tightly. Make sure the edges are flush and and check if the corners are right angled.
Assembling the frame of the chair
Continue the project by attaching the aprons. Drill pocket holes at both ends of the slats and then secure them to the sides with 2 1/2″ screws. Make sure the corners are square.
Fitting the seat cleats
Next, fit the 2×4 cleats to the frame of the outdoor sofa. Drill pocket holes at both ends of the cleats and then secure them to the sides with 2 1/2″ screws. Fit the cleats 1 1/2″ under the top edge, so you can fit the slats.
Fitting the seat slats
Next, cut the slats from 2×4 lumber and place them to the cleats. Cut a wood block at 1 1/16″ and fit it between the slats to create even gaps. Drill pilot holes through the slats and insert 2 1/2″ screws to lock them into place tightly.
Fitting the top backrest slat
Fit the 2×4 slat to the top of the back legs, as shown in the plans. Drill pilot holes and insert 2 1/2″ screws to lock it into place.
Backrest slats
Next, you need to make 20 degree bevel cuts to both ends of the back slats. Use a good miter saw to make the cuts.
Fitting the backrest slats
Drill pocket holes at both ends of the slats. Fit the slats to the back of the outdoor sofa, as shown in the diagram, and insert the 2 1/2″ screws to lock them into place.
End backrest slats
Next, cut the end backrest slats, as well.
Fitting the end backrest slats
Drill pocket holes at both ends of the slats and secure them into place with 2 1/2″ screws.
How to build an outdoor chair
Fill the holes with wood putty and smooth the surface with 120-220 grit sandpaper. Apply a few coats of paint or stain over the components. Lay the cushions (see my recommendation on the materials list) to the outdoor chair and enjoy your time in the garden.
Outdoor Chair made from 2x4s Plans
You should also check my 2×4 outdoor sofa HERE. If you like my project, don’t forget to SHARE it on Facebook and Pinterest.
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