DIY Outdoor Chair

After many requests, I’m excited to share our new DIY outdoor chair that matches our DIY outdoor couch and DIY outdoor coffee table! Now our DIY outdoor furniture set is complete!

DIY outdoor chair

It’s starting to feel like springtime in Charleston! The azaleas are blooming and the weather was sunny and around 60 degrees this past weekend. It was the perfect weather to get outside and do some woodworking!

Just like our DIY outdoor couch, the matching chair was built to go with these outdoor cushions that I love. They recently came back in stock and I ordered another set for the chair.

If you use different cushions make sure to adjust the below measurements. A reader found these other cushions which are similar in size, and this store has other outdoor cushions to choose from as well, but again measurements would still need some adjusting. Here are a few more cushion options and here as well.

The seat cushion I used is 28.75″ long x 28.75″ wide. *Make sure to get your cushions first before building in case they go out of stock!

Click below for printable build plans and an easy formula for changing the cut list for different size cushions, as well as some alternative cut list examples for common cushion sizes:

get the printable build plans

Overall, the chair build is very similar to the DIY outdoor couch, there are a few modifications and a few less 2×3 boards. But, I will still break it down step by step below and I have a full video tutorial below as well!

Also, if you are new to woodworking and building, see my woodworking for beginner’s post with 6 easy tips to get started!

Note, this post contains some affiliate links. For more info see my disclosures here.

How to build a DIY Outdoor Chair:

Materials:

Tools:

*If you use different cushions, make sure to adjust the below cut measurements!

** See the printable build plans for details on how to change the cut measurements for different cushions!**

The final size of this DIY outdoor chair is 26″ tall x 33 3/4″ wide x 30 1/4″ deep.

VIDEO TUTORIAL:

Subscribe to my YouTube Channel here!

 

1. Make cuts for outdoor chair frame

Use a miter saw and make the following cuts from the 2x3s:

  • 4 pieces @ 24 1/2″ (for side frames)
  • 2 pieces @ 30 1/4″ (for side frames)
  • 5 pieces @ 28 3/4″ (for back & front frames)
  • 5 pieces @ 27 1/4″ (for side & bottom frames)

Make cuts for outdoor chair frame

2. Add pocket holes to wood

Make sure your Kreg Jig is set to 1 1/2″ thick wood. Add two pocket holes to each end of the following 2×3 pieces:

  • 5 pieces @ 28 3/4″
  • 5 pieces @ 27 1/4″

Tip: See my how to use a Kreg Jig post for an easy, step by step tutorial and video tutorial on how to use the Kreg Jig!

Note, my pic below is missing the 5th piece at 27 1/4″ because I ran out of lumber during this step.

chair frame boards with pocket holes on ends

3. Assemble DIY patio chair side frames

The frames of this DIY outdoor chair are built exactly the same way as the DIY outdoor couch side frames. See that post for a few more photos of this step. Or you can refer to the DIY chair video tutorial as well!

Mark 10″ up from the bottom of one of the 24 1/2″ pieces. Attach one of the 27 1/4″ pieces perpendicularly to the 24 1/2″ piece at the 10″ mark. Then, attach them together with 2 1/2″ Kreg screws. Repeat on the other side.

I used a scrap 1×4 and paint stick underneath of the 2×3 to hold it up so the edges would be flush for when I attached the two boards.

assemble outdoor chair frame boards with kreg screws and drill

Also, another thing to note is that I am using 2 1/2″ indoor Kreg screws because it’s what I had on hand and my chair is going to be in a sunroom. But, if your chair is going to be totally outside, you should use the blue, outdoor Kreg screws.

Next, attach one of the 30 1/4″ boards to the top of the frame with 2 1/2″ deck screws. Make sure they are countersunk beneath the wood surface (you will fill them with wood filler later). I used self tapping deck screws that do not require pre-drilling.

Assemble DIY patio chair side frame top board with screw and drill

Assemble DIY patio chair side frame

Repeat the above steps for the second side chair frame.

4. Add side slat boards to chair side frames

Measure the exact distance between the two legs of the side frames and cut three 1x3s to this size. The measurements should be close to 27 1/4″ but since we’re working with framing lumber, they may not be. My 1x3s were about 1/16 different and I wanted the measurements to be precise so that there were no gaps!

Add each 1×3 one at a time with 2″ brad nails through the side 2×3 legs. Space them 1 3/4″ apart starting from the top  2×3.

Add side slat boards to chair side frames with brad nailer

Add side slat boards to DIY outdoor chair side frames

5. Attach sides of DIY outdoor chair together

Attach the two side frames together by attaching the front and back bottom boards (two of the 28 3/4″ boards). Use  2 1/2″ Kreg screws and a drill. Make sure that the pocket holes are facing the inside of the chair frame.

Attach sides of outdoor chair together with Kreg screws and drill

Next, add the bottom support boards using the remaining three 27 1/4″ boards and 2 1/2″  Kreg screws. Space the bottom support boards about 5″ apart. *Note: I ran out of lumber and had to use just just two boards spaced 8″ apart as shown in the photo and video. But I recommend using three bottom support boards in this step, instead of 2, for the best support!

add the two bottom support boards

6. Add back frame boards to the chair

Finally, attach the remaining three, 28 3/4″ boards to the side frames to create the back frame of the DIY patio chair (space the boards about 2 3/4″ apart).

Add back frame boards to the diy patio chair

Finished building DIY outdoor chair before adding stain

And that’s it for the build!

7. Fill holes, sand, and stain the outdoor chair

The last step is to fill the screw and nail holes with stainable wood filler. Also, finish any needed sanding. For tips on sanding wood, check out my easy guide on how to sand wood.

Finally, stain your DIY outdoor chair! I used one coat of Valspar semi transparent exterior stain in Pine bark. It was one of the only exterior stains I could find that came in a quart size and not a gallon size. See my tutorial on how to stain wood for a beautiful finish and the best way to apply stain!

Let the stain fully dry and then add your cushions!

I can’t wait to start using our new DIY patio chair. I’m glad I’ve got the full spring and summer to enjoy it now! Bring on the warm weather!! Maybe this summer I will finally makeover our sunroom too! And don’t forget to check out the matching DIY outdoor coffee table!

Follow along on my latest projects and sneak peaks on Instagram, YouTube, and Facebook!

DIY patio chair on porch

If you want to save this tutorial for later, Pin It here:

DIY outdoor chair on patio

Decor Product Sources:

Get instant access to the library of FREE printables for the home!

Subscribe and get home decor tips, DIY tutorials, and access to the library of FREE printables for the home!

Powered by ConvertKit

88 thoughts on “DIY Outdoor Chair

  1. Thank you so much for your very easy to follow video and plans for the chairs. My son and I made two of these and they turned out great!! This is the first time I have made furniture. My boyfriend wants a wooden bench for his porch and I feel confident that I can now make that.

      1. I love it! and I’m definitely going to try it! I keep you posted. Also, where did you get the white cushions? I love those!

      2. My husband and I made this couch and I used the same stain and ours doesn’t alloy anything like yours. Any suggestions on application of the stain? Mine came out very paint like looking. Thanks!

        1. It does have a paint consistency to it, I just made sure to stir it really well before applying. And to really rub it in as I applied it. You can see more of the staining process with the stain in my DIY outdoor couch Youtube video

    1. You need to adjust the length and width cuts. I have step by step directions available in my printable build plans.

  2. Thanks so much for these plans! My husband and I built the loveseat last night and are working on 2 chairs tonight so a whole patio set! World Market has been sold out of the cushions since I found this post a couple months ago- BUT a place called Totally Furniture makes a set of 28×28 cushions so I was able to order those and only slightly adjust the measurements! (It’s easier to Google search ‘TK classics outdoor cushions’ to find them- their website isn’t laid out well).
    I’ll be sure to tag you on Instagram when we’re all done and set up!

    1. You’re welcome! That’s exciting to hear! Yes another reader told me about those cushions too, almost the same size which is great!

  3. Any idea if those cushions come back in stock periodically on World Market? We foolishly built this per the dimensions you demonstrated without realizing what a difficult size those cushions are to find – and now we have two brand new built chairs with no cushions – and $200 is pretty pricey and defeats the reason we built our own furniture. A disclaimer at the beginning of the blog might be helpful.

    1. They do come back in stock but sell out quickly when they do so it’s best to keep a close watch on it. They use to have a in stock notification sign up but I don’t see that anymore. I do have a starred and italicized note about ordering your cushions first as others have had this happen too which is a bummer!

  4. I love this and want to try it. Is there a basic Kreg jig that you recommend? Something for an occasional DIYer? Thanks!

    1. I love my K4 Kreg Jig which is linked above under tools. It’s great for beginners. I know others have started with a Kreg Jig mini which is a less expensive option.

  5. How would the measurements need altered with 24×24 cushions? I tried figuring it up myself but i don’t want to mess it up.

  6. Wondering if this build can be done with out the Kreg Jig and instead just additional deck screws/wood screws? Wondering if it’ll really affect the structural integrity as I don’t have half these tools but I love the look of these so much!

    1. Thank you! Yes it can be done with just screws, but the Kreg Jig provides a much stronger joint and cleaner look. There is a Kreg Jig mini available which is cheaper if that would be more helpful. I’ll add a link to it in the tool list!

  7. Made a chair today I can’t wait to complete the whole set thank you so much I don’t do diy but this is wonderful and you helped me save so much money on patio furniture 🙌🏾

Leave a Reply

Your email address will not be published. Required fields are marked *

shares