Continuing our series on chunky outdoor furniture, here are a set of free DIY plans for a chunky outdoor chaise lounge. This chunky outdoor chaise lounge is designed to go with 5″ or 6″ deep cushions to give an ultra-comfortable lounging experience. Though unlike the accompanying chair and loveseat, these plans do not have the seat reclining at a 5° angle. These plans keep the seat parallel to the ground.

Materials Needed

• 3 – 4×4 at 8′ (I recommend cedar)
• 1 – 1×2 at 6’
• 5 – 2×4 at 8’
• exterior wood glue
• 5″ structural screws
• 2 1/2″ exterior pocket hole screws
• 4” exterior pocket hole screws
• 2 1/2″ exterior wood screws
• sealant, stain, or paint as desired
• 1 – outdoor chaise lounge cushion set

Tools

• Miter Saw or circular saw
• Drill/Driver and counter sink bit
• XL pocket hole jig
• 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 chaise lounge by building the two leg assemblies. These are similar in design to thise used in our chunky outdoor chair plans, however the seat does not slope back at all. Remember, you need to build two sets of legs that 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.

• 2 – 22 1/2″ 4×4 for front legs
• 2 – 23 15/16” 4×4 with parallel 20° miters for back legs
• 2 – 17” 4×4 with one end 20° mitered for arm rests
• 2 – 20 3/4” 2×4 with one end 20° 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 and rear legs. Make certain both legs are sitting on a flat surface so the chaise will sit flat when complete. For the armrest, cut three pocket hole screws on the underside of the armrests and use wood glue and 4″ pocket hole screws to attach it. Note, I wouldn’t normally recommend using pocket hole screws to attach 4x4s, but considering these armrests shouldn’t see much weight, the pocket hole screws should do just fine.

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, 31 1/2″” 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, 1 1/2″ from the front face of the backrest 4×4. Use wood glue and the 2 1/2″ exterior screws to attach it, making certain to pre-drill with a countersink bit. I like to attach this first, with the top edge aligned to the top of the 4×4 then use a hand saw to cut the bottom edge flush at the 20° angle.

Step 3: Build and attach seat supports

For the long runners of the seat base, you’ll need to cut two 2x4s to 42″ in length with a 20° miter on one end of each. Use wood glue and 2 1/2″ wood screws to attach these to the seat supports of each leg assembly.

Next, cut two 12″ pieces of 4×4 and use three pocket hole screws on the inside end of each long runner to attach them to the 4×4 posts. Align the outside of the posts flush with the outsides of the long runners.

Lastly for this step, cut a 16 1/2″ piece of 2×4, drill 3 pocket holes on each end and attach it flush to the top and outside of the 4×4 feet. Remember to put the pocket holes on the inside!

Step 4: Add seat and backrest slats

The last steps in building this chunky outdoor chaise lounge are going to be simple. Cut nine pieces of 2×4 at 20 1/2″ in length, then drill three pocket holes on each end of these slats. Start by attaching the front slat using wood glue and the pocket hole screws from underneath, then do similar for your rear slat, then equally space the remaining seven and attach.

Cut four more pieces of 2×4 at 16 1/2″. Then use wood glue and the 2 1/2″ wood screws to attach them to the 1x2s on the backrest per the diagram below.

Step 9: Sand and finish

Now that the assembly is complete, it’s time to give this chunky outdoor chaise lounge 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.

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