PROJECTS: ROK-BAK CHAIR
2d. Cross brace B: Attach the backstop, a 22"× 1¼"×½" strip of
plywood that will support both seat and back pieces. This extra
piece of plywood catches the bottom of the back, which then
stops the seat. Use three #8× 1½" wood screws, spaced approximately 8" apart.
2e. Cross brace D: For the footstool, cut a 15" length of 2× 4 and drill holes in the ends as you did on the
other braces. We’ll make the other miscellaneous parts after test-assembling the chair.
3. ASSEMBLE THE BASIC CHAIR
3a. Prop the sides apart while you fasten the cross braces
between them using the lag bolts and washers.
WARNING: Don’t scrimp on the size of these bolts, or your chair and/or
stool could disassemble itself dramatically! Before you add the seat
and back pieces to the chair, check for smoothness of all surfaces and
edges. This is not only an appearance issue, but an obvious comfort
issue as well.
3b. Drop the back ( 3 screw holes up) and seat (any orientation)
into their respective positions. Notice that the bottom of the back
fits between the rear edge of the seat and the backstop on cross
brace B. Do not sit yet!
3c. IMPORTANT: With the seat and back pieces flush with the
wide side of all 3 cross braces, fasten the back to cross brace A
with three #8× 1½" flathead wood screws. These screws prevent
braces A and B from rotating; your weight will keep brace C fixed.
3d. Now throw in a patio chair cushion set and give your chair a
test-sit. The back cushion should rest on top of the seat cushion,
whether they’re a stitched assembly or separate cushions. I’m
5' 11", 150lbs, and the chair fits me perfectly. If you’re shorter,
you can trim the sides along the bottom so that your feet will be
well supported when you sit in the chair.
3e. If you’re sure you want to build only the basic configuration,
you can make the large bottom cutouts in the sides as shown in
the plans at makezine.com/19/rokbak. However, if you’re building
the Rok-Bak version, leave the sides solid for now.
CAUTION: Don’t be tempted to make cutouts in the sides under the
seat. This will almost certainly make the chair too weak and wobbly.
94 Make: Volume 19