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’
• 3 – 2×4 at 8’
• exterior wood glue
• 5″ structural screws
• 2 1/2″ exterior pocket hole screws
• 4” exterior pocket hole screws
• 2″ exterior wood screws
• sealant, stain, or paint as desired
• 1 – outdoor seat 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 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 – 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 (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 it fits tightly, 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, 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, 1 1/2″ 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 six pieces of 2×4 at 23 1/2″ in length to make the seat slats. Then drill three pocket holes on each end of these slats. Start by attaching the front stretcher slat, aligned flush with the front of legs and so the top of the 2×4 is 12″ from the ground. Then attach your front 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 three more pieces of 2×4 at 16 1/2″. Then use wood glue and the 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 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.

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