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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!

Cushions Used & Cushion Options

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 similar cushions which are the closest in size that I have seen (they are 28 x 28″, the ones I used were 28.75 x 28.75″).

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 here 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!

Spring 2021 Cushion Update: World Market currently has more cushion options in very similar sizes to the cushions I used which are still out of stock, here are the new options:

Printable Build Plans & How to Change the Cut List for Different Cushions

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!

If you make this DIY chair, please share it with me on social media @angelamariemade or #angelamariemade! *You can also share your build in our Woodworking for the Home facebook group, be sure to join! 

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

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Tyler

Monday 19th of April 2021

Just a tip for other readers: if you are making 2 or more chairs you can use 1-2 less boards by organizing your cuts to maximize board usage. I am making 2 chairs using nine 8ft. boards by mixing and matching my cuts on the boards to utilize as much of the 8 feet as possible. With how much lumber prices have increased since this DIY project was posted this may be a nice money saver. I found a great board-usage maximizing calculator here: https://jonathan.overholt.org/projects/cutlist

Regina

Sunday 18th of April 2021

Thanks for a great chair plan and all the cushion links. I was able to snag 2 sets of cushions FIRST - and hubby managed to get 2 chairs assembled this weekend before the rain came. Some filling, sanding and finishing left to do - but we gave them a quick field test and they are EXACTLY what I wanted - will be perfect seats for the backyard movie nights ahead.

Angela Marie Made

Monday 19th of April 2021

That is so great to hear, thank you so much for sharing!!!

Aisha Haiyoom

Friday 16th of April 2021

Hi, I'm interested in making this. Can you tell me how the chair and the couch have held up over the months since you made them? Have they become wobbly or unsupportive over time? Have you had to tighten them? Thank you!

Angela Marie Made

Sunday 18th of April 2021

They have held up great over the past few years, I haven't had to make any adjustments and they have gotten a lot of use!!!

Joseph

Tuesday 6th of April 2021

What Gauge Brad Nail did you use? 18 GA or 16 Ga

Joseph

Thursday 8th of April 2021

@Angela Marie Made, Awesome thank you!

Angela Marie Made

Wednesday 7th of April 2021

18 ga

Megan walden

Thursday 1st of April 2021

I purchased the chair build plans and i’m not sure where it even downloaded i checked what i got and it was a bunch of numbers and letters no build plans?

Angela Marie Made

Wednesday 7th of April 2021

Hey Megan, send me an email letting me know what email address you used so I can look it up and get this straightened out. thank you!

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