With spring coming on I’m starting to feel like it’s time to make some new outdoor furniture, starting with these chunky outdoor chair plans. These chunky outdoor chairs are designed with the seat relaxed back at a 5° angle and to go with 5″ or 6″ deep cushions to give an ultra-comfortable lounging experience. These are the first plans in a new series we are doing on chunky outdoor chairs, loveseats, and chaise lounges.

Materials Needed

• 2 – 4×4 at 8′ (I recommend cedar)
• 1 – 1×2 at 6’
• 1 – 2×4 at 8’
• 2 – 1×4 at 8′
• 1 – 1/2″ dowel at 2′
• exterior wood glue
• 5″ structural screws
• 2 1/2″ exterior pocket hole screws
• 4” exterior pocket hole screws
• 1 1/2″ exterior wood screws
• 2″ exterior wood screws
• sealant, stain, or paint as desired
• 1 – outdoor seat cushion set

Tools

• Miter Saw or circular saw
• Drill/Driver
  • counter sink bit
  • 1/2″ drill bit
• XL pocket hole jig
• 5 – 1/2″ dowel centering pins
• Sander and sandpaper
• Square and protractor
• Tape Measure
• Quick-grip bar clamps (optional)
• A right-angle clamp comes in handy when doing pocket holes too

Step 1: Build Leg assemblies

We’ll start building this chunky outdoor chair by building the two leg assemblies. These are mirror images of each other. So both assemblies will have the 2×4 seat support flush to the inside of the 4x4s. The cut list for these boards is below. Note we state the armrest board is 17″ in length on the longer side. As you assemble the pieces, the armrest will most likely wind up needing to be cut down slightly shorter than this.

• 2 – 19″ 4×4 for front legs
• 2 – 20 1/14” 4×4 with parallel 20° miters for back legs
• 2 – 24 1/2” 4×4 with one end 20° mitered for arm rests (will trim shorter later)
• 2 – 21 1/2” 2×4 with one end 25° mitered for seat supports

Once you have the pieces cut for both leg assemblies, cut three pocket hole screws on the inside of each end of the 2×4. Use wood glue and 2 1/2″ pocket hole screws to attach this to the front leg so that the top front edge is 12″ high on the front leg. The rear will get attached just over 7″ from the base of the back leg. Make certain both legs are sitting on a flat surface so the chair will sit flat when complete. For the armrest, you’ll want to dry fit it in between the front and back legs. You may have to trim a bit off of one end.

Once you have the armrest cut to final length we’re going to drill five 1/2″ holes 1″ deep into the top of both the front and back legs. To do this, draw an X on the top of each leg and then drill one hole in the center and one on midway to each corner. Now, insert your five dowel centering pins and push the armrest down firmly ensuring it is aligned correctly. Repeat for the back leg. You should now have the layout for drilling the holes on the bottom of the armrest that will be aligned to the holes on the legs. Glue a 2″ long piece of 1/2″ dowel into each of the holes in the legs. Then cover the top of each leg and the protruding dowels with exterior wood glue and attach the armrest. Use clamps or heavy weights to squeeze it into place until the glue dries.

Step 2: Add backrest supports

After you have the leg assemblies built, it’s time to add the supports for the backrest. Start by cutting two 4×4 pieces, 25″ in length, with a 20° miter on one end. You’ll attach these 4x4s to the leg assemblies using wood glue and the 5″ structural screws, going through the backrest 4×4, into the leg assembly. You’ll want to line the bottom of the 4×4 backrest up with the bottom of the 2×4 seat support, and bump the face of the backrest support up to the upper corner where the 2×4 seat support meets the back leg. Use the quick clamps to hold the backrest 4×4 in place, then pre-drill and attach.

Now you’ll need to add a 1×2 support, 3/4″ from the front face of the backrest 4×4. Use wood glue and the 2″ exterior screws to attach it, making certain to pre-drill with a countersink bit.

Step 3: Attach seat slats

You’re now onto the easy parts of these chunky outdoor chair plans! You need to cut five pieces of 1×4 at 23 1/2″ in length to make the seat slats, and one piece of 2×4 at 23 1/2″ for the front stretcher. Then drill three pocket holes on each end of these slats. Start by attaching the 2×4 front stretcher, aligned flush with the front of legs and so the top of the 2×4 is 12″ from the ground. Then attach your 1×4 front seat slat, then your rear slat, then equally space the remaining three. There should be about a 1/2″ gap in between each of the five seat slats. Remember to have your pocket holes hidden on the bottom side of the chair!

Step 4: Add backrest slats

The last step is going to be simple too. Cut four more pieces of 1×4 at 16 1/2″. Then use wood glue and the 1 1/2″ wood screws to attach them to the 1x2s on the backrest per the diagram below. Make certain to predrill with the countersink bit so you don’t split your slats!

Step 5: Sand and finish

Now that the assembly is complete, it’s time to give this chunky outdoor chair a good sanding. You don’t want your guests getting splinters! If you used non-treated lumber, take the time to add a coat of paint or outdoor stain to help it stand up to the elements. Now add some cushions, then sit back and enjoy your handiwork!

Not certain what type of finish you want to add to your new piece? Check out our series on eco-friendly wood finishes. We detail options for oils, waxes, water-based finishes, shellac, milk paint, and citrus and plant based solvents. We give you all of the details you need to make an informed choice about the right type of finish to choose for your latest project.

If you have comments or question, please feel free to connect with us via the comments section below or use our Contact Form.  We love the feedback!  Also, don’t forget to check out our other free DIY furniture plans.

Don’t forget to show off your work in our Share Your Build section. We truly appreciate it when people share their work and let us know how our plans turned out for others.

Recommended Reading

Looking to dive deeper? Here are a few related projects and guides that will help you sharpen your woodworking skills, discover new techniques, and find inspiration for your next build.

• Why cedar makes great outdoor furniture and what to substitute on a budget
• How to choose the best wood for your project
• DIY modern outdoor dining table plans

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