Beach Chair | Woodworking

Steps to build your Beach Chair

Step 1 - Board layout

Get a 2 by 6 from the lumber rack. Wood for the 36" pieces is on the second shelf. Laid out the cut lines on your board. You will need 2 pieces 36" for your chair supports and 1 pieces at 20" for your seat slats.

Beach Chair IMG_3908 compressed_edited.j

Step 2 - Rough cut on CMS

Rough cut all your boards on the Compound Mitre Saw.

You now have options - You can work on your slats or cut the chair legs.

How do you decide?

Is there a long list on the jointer? Start OPTION 2. Please still put your name on the jointer list so that you can get the first couple steps done on Option 1.
Is there a long list on the Band saw? Start OPTION 1
You can alternate between option 1 and 2 step depending on how busy the machines are!
If machines get busy and you are at anytime waiting for a machine, THINK, what other step could I be doing on my project? LOOK AT THE STEP OF THE PROJECT, what other step could I be doing on my project? There is almost always sanding that can be done.

Option 1 -

Cutting your seat slats

Step 3 - Face Side

On the Jointer, jointed ONE face side on each of your 20" seat slats wood. Put an X on the side after it has been jointed.

Step 4 - Face Edge

On the Jointer, jointed ONE face edge on each of your 20" seat slats wood. Choose the nicest looking edge to cut .

Step 5 - Thickness

Planed all your boards to 1 5/16" thick on the planner or as thick as possible.

Step 6 - Sand

Sand the sides of your 20" boards.

Sand with 80 Grit (Blue)
Sand with 120 Grit (Red)
Sand with 180 Grit (Green)

Step 7 - Width (ripping)

On the table saw, rip the slat seats to 3/4" wide. Find a partner, so you can both work together to cutting and catching the wood on the table saw. You will need 16-17 slats when you are done.

Step 8 - Router the edges

Using the plywood router table, router the end grain of your good side of your slat wood. You will be using a mitre gauge on the router table to ensure your routering is cut correctly.

Step 9 can be done anytime after the slat wood has been cut

Step 9 - Sand

Using an electric sander. Sand all edges and sides of your slat wood.

Sand with 80 Grit (Blue)
Sand with 120 Grit (Red)
Sand with 180 Grit (Green)
Sand with 220 Grit (Black)
Put your initials the bottom side of your project to prevent theft.

Option 2 -

Cut your chair legs

Step 10 - Layout out pattern

Layout the pattern to cut the bottom and back chair legs. The patterns are kept at the front of the room, on the plywood jig wall, close to the top of edge of the plywood. Trace this on to your board.

Step 11 - Cut on the band saw

Cut on the line between the bottom and back chair legs.

You will need a helper to caught you wood.
You will be keeping both side so make sure you take your time and following the lines while cutting.

Step 12 can be done at anytime

so move on to another step if the sanders are busy

Step 12 - Sand

Using an electric sander. Sand all edges of your wood. DO NOT PUSH ON THE SANDER, hold the sander and let it do the work. You will wreck the sander if you push on it.

Sand with 80 Grit (Blue)
Sand with 120 Grit (Red)
Sand with 180 Grit (Green)
Sand with 220 Grit (Black)

Next step on the Beach Chair

Step 13 - Layout the drilling pattern on the slats

Find the drilling pattern for the bottom and back slats.

The patterns are kept at the front of the room, on the plywood jig wall, close to the top of edge of the plywood.
You will need the 7 nicest/longest pieces to make bottom (seat) slats. Use the correct jig, line up the jig on top of your wood, making sure the edges match. Then push down on the pattern and the screws on the pattern will make a small indent into your wood. This indent is where you will drill holes next.
Repeat with the back slats using the correct jig.

steps 14, 15,16 can be done anytime

after the slat wood has been cut

Step 14 - Drill the counter sink hole on the slats

Using the indent made in step 14, drill a counter sink hole from the good side of your wood.

Place your wood in your vice.
You want to drill until the counter sink hole is about about 1/8" deep (about 3 mm).

Step 15 - Drill a 3/16 hole in the center of the counter sink hole on the slats

Place your wood in your vice.
You want to drill until the counter sink hole is about about 1/8" deep (about 3 mm).

Step 16 - Put your initials close to your drill holes this will prevent theft.

Step 17 - Router End grain of the slats on the wooden table router.

Using a 1/4 round over bit.

router both ends of all your slats on the wooden router table.

Step 18 - Router Side grain of the slats on the table router.