How to make a single seater chair set

Cutting List:
21 mm plywood sheet cut to:

• 8 @ 630mm x 94mm
• 20 @ 600mm x 94mm
• 4 @ 650mm x 94mm
• 8 @ 608mm x 94mm
• 4 @ 610mm x 50mm

For your convenience, have Builders cut your timber to size.

One piece of 21mm Ply makes 2 chairs.

Preparation

Start by making the two box sides of the chair structure: You will need 2 x 608mm x 94mm, 2 x 630mm x 94mm, 1 x 650mm x 94mm and 1 x 610mm x 50mm slat for each side box structure.

Step 1

Begin by drilling pocket holes on both sides of the 608mm x 94mm slats.

Step 2

Now drill pocket holes on only one side of the two 630mm x 94mm slats.

Step 3

Using wood glue between the mating surfaces and Kreg Screws, fasten one of the 608mm x 94mm slats to the two 630mm x 94mm slats on the side without Kreg pocket Holes. Make sure the un-used Kreg pocket Holes are on the outside of the box.

Step 4

Again using wood glue between the mating surfaces, fasten the 650mm x 94mm piece to the two 630mm x 94mm pieces with Kreg Screws.

Step 5

The last 608mm x 94mm piece will help form the seat brace and needs to be fastened perpendicular to the two 630mm x 94mm slats with an offset of 250mm from the bottom, again using wood glue and Kreg Screws.

Step 6

Now to complete the seat brace, fasten the 610mm x 50mm piece to the slat installed in step 5. This needs to be offset by 21mm (thickness of timber) from the top edge of the slat installed in step 5, again using wood glue and Kreg screws

The box sections are complete

Repeat these steps to create a total of 4 side box structures. With all the box sections complete, it is now time to join them together with the 600mm x 94mm slats

Step 7

Start by drilling pocket holes on both sides of all twenty 600mm x 94mm slats. Kreg and pile of drilled slats

Step 8

Now take one side box structure with the back edge face down. Take four 600mm x 94mm slats and align the first with the top edge, the second with the seat slat brace and the others evenly in-between. Fasten those in position with wood glue and Kreg screws.

Step 9

Fasten the opposite side box structure with the same alignment using wood glue and Kreg screws.

Step 10

With all the back slats secure, flip your chair so the front face is face down. Now align one 600mm x 94mm slat with the seat slat brace and fasten with wood glue and Kreg Screws.

Step 11

With your chair structure sitting the right way up, align one 600mm x 94mm slat in the centre and then evenly space the remaining four 600mm x 94mm slats over the seat brace before fastening with wood glue and Kreg screws.

Structure is complete

Your structure is now complete. Repeat these steps to complete the second chair. With your structure now complete, you can now customise the look to suit your style and home.

Step 12

Start by filling all the Kreg pocket holes. You can use Kreg Pocket Hole Plugs or wood filler.

Step 13

Disguise any other imperfections in the timber with wood filler.

Step 14

Once the wood filler has dried, give your chair structure a good sanding before dressing the timber to suit your style and home.

Step 15

We used the Fired Earth Cabinet and Furniture Paint as it is so easy to use and is hard-wearing.

Step 16

As an optional extra, you can now add some rubber feet to the bottom of your chairs which will help protect both your chairs and floor surfaces.

Complete

A modern home made piece of furniture made from just one sheet of plywood. Be sure to see the table and double seater designs to complete the set.