SET UP.
M
B
D
E
F
P
MATERIALS
FOR THE CHAIR ONLY:
[A] Patio chair cushions,
4"– 5" thick ( 2) stock
or custom. Ideally get a
22"× 40" stitched-together
pair; alternately, get 2 sepa-
rate cushions, each 22"× 20".
Big-box stores carry patio
cushions, and fancier cush-
ions can be found online in
lots of colors and designs for
a bit more money.
[B] Varnish or polyurethane spray preferred
Photography by Larry Cotton
[C] Spray adhesive for
holding foam on arms during
upholstery
[F] ¼"× 2½" lag bolts ( 10)
[D] #8× 1½" flathead wood
or drywall screws ( 22)
[E] u"– 7" ID washers
( 10)
L
K
C
N
O
Q
R
G
[G] 2× 4 fir or pine,
8' length for cross braces
[H] 1× 4 fir or pine,
6' length for arms
[I] ½" plywood, 4'× 8'
sheet, A-C interior grade
(minimum)
FOR THE FOO TSTOOL
AND HEADREST:
[J] Hook and loop
fastening material
(velcro), 30in2
[K] Fabric bonding tape,
½"– 3" wide such as Stitch
Witchery. This is an alternative to sewing.
[L] 1yd of 54" or 60"
upholstery fabric Material
for upholstery is abundant at
mill outlets. I used denim for
my deluxe chair, which looks
good, is easy to work with,
and (you guessed it) cheap.
A
J
H
I
[M] Staples, with 2" leg
( 1 box)
[N] Spool of white thread
(optional)
[O] 4oz (minimum) pillow
stuffing such as Holofil or
Nature-fil, for the headrest
[P] Medium-density foam,
29"× 19"× 1½" thick from
a foam store or upholstery
shop. Medium density
weighs about about 1lb/ft3.
[Q] 1" wood dowel,
8½" length for the headrest
[R] 2× 2 fir or pine,
3' length for footstool
top supports
[NOT SHOWN]
¾" foam, 7"× 25" or you can
re-saw 1½"-thick foam
TOOLS
Jigsaw with plywood blade
Circular saw (optional)
with plywood blade
Sander with various grits
of sandpaper Random orbit
is best.
Drill with drill bits and
screwdriver bits
1½"– 2" diameter
drum-sander accessory
for drill with 60-grit paper
8" ratchet wrench
A manual ratchet is OK, but
an accessory for your drill
is faster.
Sharp pencils with erasers
Standard 15oz can You may
eat the contents, but save
the can.
FOR UPHOLSTERING:
Scissors or shears
Electric knife (optional)
for cutting foam
Band saw (optional)
if you’re re-sawing 1½" foam;
otherwise buy ¾" foam
Staple gun
Sewing machine or
clothes iron for sewing or
hot-taping fabric seams
91 Make:
