DIY Network

Adirondack Chair: Legs and Front Assembly From "Woodworking" episode DIW-209

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Johnson created his Adirondack chair from cypress, which offers high resistance to water and sunlight (as do cedar and redwood). Although it's a less expensive option, pine should be avoided. The reason? Pine requires painting and the constant touch-ups add to the overall cost, time and effort needed to maintain the beauty of the finished project. Figure A Figure B Figure C Figure D Figure E

Adirondack furniture -- like the chair in this project -- has been an enduring rustic style since the early 1900s. DIY Woodworking host Bruce Johnson says this beginner's project should cost less than $60 per chair -- hundreds less than you'd pay at a furniture store, lawn and garden shop or specialty retailer.

Materials:

Jig saw
Woodworker's glue
Cardboard template for legs
Drill with combination countersink-pilot bit
Galvanized screws
Tape measure, ruler or yardstick
Dark pen or marker
Wood clamps
Band saw
Construction square or combination square
1 piece of 3/4" x 3 1/2" x 23" wood (front seat support)
2 pieces of 3/4" x 3 1/2" x 21" wood (front legs)
2 pieces of 3/4" x 5 1/2" x 35" wood (back legs)

1. Begin by notching the two front legs (cut to 10 3/4" long) with jig saw, create notches 3 1/2" wide.

2. Apply woodworker's glue to cross-piece (seat support) and position within the notches (figure A).

3. Countersink two pilot holes (figure B) and drive screws (figure C).

4. Stand front assembly up and use clamps to hold assembly upright.

5. Use dark pen to trace leg pattern onto wood.

6. Then, use band saw to begin making relief cuts (figure D) at areas of stress.

7. Next, use band saw to finish cutting leg. Make shortest cuts first, cutting just outside the line. Cuts should be made slowly and steadily to prevent splintering of wood.

8. Use woodworker's glue to hold leg into position. Use square to insure alignment. Then, clamp to hold in place as it dries.

9. Drill holes into the back brace into the legs using a special combination bit (figure E) -- Johnson's uses one that has both pilot and countersinking abilities.

10. Add back brace across center of legs, using screws to attach.

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RESOURCES :

The Wood Finisher: How to Finish Everything, From Decks to Floors to Doors
Author: Bruce Johnson
ISBN: 0345372972
Ballantine Books

Finishes for Exterior Wood: Selection, Application and Maintenance
Model: 0935018832
Author: R. Sam Williams, et al

Outdoor Wood Furnishings: 35 Easy Projects for Your Yard
Model: 0865736332
Author: Creative Publishing International

176 Woodworking Projects: A Workbench Treasury
Model: 0806965282
Author: Workbench Magazine

To order this title from Amazon, click here.

Shop Tested Outdoor Furniture You Can Make: From the Editors of Wood Magazine
Model: 069620746X
Author: The Editors of Wood Magazine

The Woodworker's Guide to Furniture Design: The Complete Reference. . .
Model: 155870437X
Author: Garth Graves
Betterway Books (F & W Publications)
Website: www.fwpublications.com

American Woodworker Magazine
American Woodworker
Website: www.americanwoodworker.com

Building Adirondack Furniture : The Art, the History, and the How-To
Model: 091358987X
Author: John D. Wagner

Build It Yourself: Adirondack Chair
Model: 1880029634
Author: The Staff of Creative Homeowner Press

Easy-To-Build Adirondack Furniture
Model: 1580172644
Author: Mary Twitchell

Outdoor Furniture for the Backyard Builder : Easy-To-Build Projects for the Yard & Deck
Model: 0762101806
Author: Bill Hylton, et al

Building Garden Furniture: More Than 30 Beautiful Outdoor Projects
Model: 0806983752
Author: Ray Martin, et al