Estimated Cost: $$$$
Total: 5 hours
A lounge chair offers a perfect spot to rest after a long day. This chair fits a 26" cushion and features storage where this can be placed when not in use. It also has an adjustable backrest to allow for different backrest angles.
The sturdy nature of this project means it will last for years and will likely become a family favorite.
To build it, start with building the frame and integrated storage, then clad the seat portion, and complete it with the backrest and support. After a light sanding and coat of protectant, this project is ready for some serious relaxation.
Note: Lounge cushion not included.
Lounge Chair (+ Hack)
To create the four outer walls, begin by attaching Parts (A) perpendicularly to a Part (B) where the edges are flush and the top of Part (A) is overhung by ⅞". Use ¼" spacers and two 1⅝" screws at a diagonal per joint.
Repeat on the other end of Parts (A). Slide two Parts (B) underneath that are 23¼" from the inside of the first Parts (B). See diagram on Page 8 for layout.
Repeat to form a second identical wall.
For the two short walls, attach a Part (C) perpendicularly to a Part (B) where the top of Part (C) is overhung by ⅞" and the edge is overhung by 2⅛".
Use ¼" spacers and two 1⅝" screws at a diagonal per joint. Fill in the lower boards to both short walls. Double-check that all Parts (B) extend the same amount for all four walls.
With Parts (B) touching the ground plane, place a short wall on the outside of the two long walls and clamp as needed. Secure the walls together at their edges using 1⅝" screws and into their mating 2x4 using 2½" screws.
Repeat on the other end until you have a completed frame.
Flip the frame so that a long wall is on the work surface. Then, attach Parts (D) 2" above Part (B) where it is protruding. Use 2½" screws per joint.
Continue securing the two Parts (D) at either end of the frame.
Next, flip the frame right-side up and take a Part (E) and secure it to the front inside of the assembly using 1⅝" screws.
Attach three more Parts (E) at each intersection of Part (B).
Then lay three Parts (F) perpendicular to Parts (E), making sure they are evenly spaced. Secure at each intersection of Parts (E) with four 1¼" screws.
Finally, attach two Parts (G) so they are flush with the top edges of the front four Parts (B). Secure at intersections with Part (B) using 2½" screws. The assembly is now oriented where Parts (G) define the back. The front is where the backrest will be positioned.
Place thirteen Parts (H) onto Part (G), beginning from the back. Mark a line for screw placement that is 2" in from the edges of Part (H). This will ensure you connect Parts (H) with the Part (G). Use 1⅝" screws.
Work your way toward the front of the assembly using ¼" spacers in between the boards. Pause after the thirteenth board.
On a work surface, place two Parts (I) ¾" under and 5" inset from the detail-cut Part (H).
Ensuring all edges are square with each other, secure Part (H) to Parts (I) using 2" screws.
Direct-measure the cavity left in the frame and, subtracting ¼", let that dimension dictate the total length of the backrest. Evenly space the boards the appropriate dimension. Ensure the assembly is square as you go.
Flip the assembly over and place Part (J) evenly between the Parts (H) and about ¼" from the edges of Parts (I). The gap is to ensure the parts do not rub when the backrest is rotated.
Keep pressure on Part (J) and lay in two Parts (K) as shown. Orient them so that the radiused corner is away from Part (J) and facedown.
Maintaining the gap from Part (J) to Part (I), secure Part (J) to Parts (K) using two 2" screws placed at a diagonal per joint.
Remove the fourth slat down from the top of the backrest assembly so the drill has space to drill Parts (I) and (K). Make the hole approximately equidistant from the edges of Parts (K), or 13½" up from its base. Use a ¼" drill bit and make holes on either side.
Add a washer under the carriage bolt head and hammer it into place on either end.
Place a washer and nut and tighten the nut using an adjustable wrench.
Replace the missing backrest slat.
Test that the pivot points rotate and rest smoothly.
Attach the lower part of the hinge to the seat portion of the assembly, ensuring that when it is in the closed position, the barrel doesn’t extend above the seat slats. Use the provided screws and appropriate bit.
Place the backrest assembly into place facedown and attach the top portion of the hinge. Before securing all screws, test that the assembly folds flat in both directions.
Next, secure Part (L) from the outside using 2" screws. Make sure it is flush with the top and side of Part (B).
Secure the second Part (L) on the other side as shown.
Finally, fold back the backrest assembly and test that the three slot positions work properly.
Ease any sharp edges using a radial sander or sanding block with medium grit. Apply preferred finish to the wood.