Published at Thursday, September 13th 2018. by Hattie Livingston in Ottoman Chair.
The chair seat and I are gonna cut a rabbet on both ends and while I have the table saw setup, I'm going to cut all the pieces at one time now, after Making the first pass I'm going to set my table saw up again to make the second pass. Now you can run test cuts on scrap pieces of wood just to make sure you get this right, it's an outdoor chair, so it doesn't have to be perfect. Now, there are many ways to do this you don't have to use a table saw so I'm also going to show you another method to accomplish the same thing.
I'm using this thinner piece of wood as a guide because this is what the four by fours would rest on now after tracing out that piece of lumber onto the 4x4, then I'm gonna take a reciprocating, saw and then cut this section out. Now you have a total of three lumbers to cut this way, so a total of six of these one on each side. You can also use a circular saw or a handsaw and right now we're still prepping the seat. So we have two more pieces to address, and these are gonna, be the outside of the seat later on in the video you'll, see where I'm going it with this, but for right now we need to cut this out. I also want to make sure to mark these two pieces together, so I don't run into any mistakes now.
This will also be duplicated on both ends. Now you can use a handsaw and a chisel to cut this out, but I'm gonna cheat a little bit by using a multi-tool and with all four pieces being cut out. I can now test the pieces and make sure everything looks good, and now all the prep work is done. I'm gonna start by setting up the arms of the chair, I'm going to put glue at every joint in this chair, and this would not only make the chair super strong, but also you don't have to worry about any squeaks a few years from now, depending on the wood glue you're using you really need to apply the glue and apply clamp right away. You don't have a ton of weight time and one thing to keep in mind.
If you don't have large clamps, you can use ratchet straps to bolt this together. I'm gonna use five-inch lag screws. I'm only gonna use, one per joint, which also makes a great reason to use the wood glue. The next thing I did was found a very center of dislocation. Then I took a 7/8 bit and drill a hole. Approximately one and a half inches deep next take a small bit and drill in the center of that hole into the next lumber behind it now drive the lag screw from one lumber into the next one. Now repeat this going around the entire army, you should have four bolts per arm now, just repeat the same thing for the other arm.
So now I'm gonna set up the two arms so that we can attach the back and also the bottom for the seat. In order to keep the seat the same height at the front and also at the back, I'm going to use some scrap pieces of wood. Now, with these pieces clamped in place, I can now add wood glue and then clamp. The structure together now take the same pieces of scrap wood and we're gonna put nose on the front leg so that I can set the front part of the seat in place.
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