Festival Chair Tutorial

This is a great chair for music festivals, the beach or park.  It folds flat and will fit in even the smallest car storage area.

1.      8 ft. 1x2 (.75x1.5) hardwood
2.      6ft  hardwood lattice (approx. .25x1.5)
3.      4.5 ft hardwood stop (approx. 3/8 x 1.25)
4.      40 #8 screws
5.      24 7/16” Upholstery nails
6.      Gorilla Glue or wood glue, Sand paper, Danish Oil
7.      Fabric
·        18” x 18” fabric for back (sunbrella or vinyl)
·        Optional Pillow : .5 yd fabric, 1 11 x13.5 pillow form
Tools: Jigsaw and circular saw (opt), Drill, square, Counter sink bit, hammer, chisel, clamps.

Overview:  This chair is composed of 2 parts:  The seat and the back.  The seat slides into the back to make the chair, and will “nest” into the back for flat storage.  In making the chair parts, it is important to make sure that the width of each piece is accurate so that the chair will fit together.   All screw holes need to be pre drilled and countersunk.  Project time < 3hours.
CUT LIST—  Cut all pieces.  Sand the faces and round over all the edges  and organize into seat and back piles.
•          2-  27.5 inch 1x2
•          4   13.5 inch  stop
•          2  20.5 inch 1x2
•          5  13.5 lattice

1.      Cut one end of each 27.5” 1x2 as shown a 45 degree angle starting 1/2 inch from the end.
2.      Mark for the mortised notch for a double piece of stop, ---- inches from 45 degree end as shown in picture below..  Use the jig saw to make short cuts up to the line, then chisel to chip out the pieces and smooth the areas.  Sand to smooth.
3.      Place stop pieces into mortised notch.  Use square to line up pieces at 90 degrees—outside measurement should be 13.5 inches. Drill and countersink 2 holes evenly spaced and centered .  Dampen each piece and add a drop of gorilla glue.  Attach with screw driver being careful not to over tighten.  Use manual screw driver for last few turns.

4.      Attach other two pieces of stop on opposite side of the back rail from the mortise 1 at the top of the chair, the other _____ inches from the end.  Drill and countersink.  Make sure to check for square--outside measurement at top and bottom of rail should be 13.5” When all is well, dampen, gorilla glue, screw.

            Cut one end of each of the 20.5” seat rails as shown for the ground rest (this is the steeper angled cut) .

      Line up seat rails inside back rail.  This will ensure that the seat section fits inside the back.  The outside measurement for the seat rails should be 12”
     Line up 5 slats starting 1/2 inch from flat end.  Space slats 1/2 inch apart. From first slat to last will be 10 inches.  The ends of the slats should line up with the edges of the back rails. 
      Check for square and then pre drill and counter sink 2 holes on each side of each slat.  Dry fit with a couple of screws per slat.
            TEST FIT.  Slide seat into back and test it out.  If it doesn’t slide in check for square and correct size, adjust as needed. 

      When it fits-- Dampen both pieces, place a drop of gorilla glue, and then attach slats. 

1.      Lightly sand both pieces (you can do this while you are waiting for glue to set)
      Select your vinyl back and cut to correct dimensions.  Sew binding along one edge. 
      Use chisel or utility knife to chip off any excess dried gorilla glue
      Apply Danish oil liberally with foam brush.  2nd coat can be applied after 15 minutes. Allow to set for 30 minutes. Wipe off excess with rag until dry. 
       WAIT 24 HOURS for finish to cure.

5.       ATTACH SEAT BACK Fold over ends of seat back so that it will be centered on the back stiles.  Attach to back with upholstery nails on one side at top, middle and bottom.  Stretch to other side (adjust fold if needed) and attach nails to top middle and bottom.  Attach remaining nails, alternating between sides until done.  
     Cut 2” foam to 11 x13.5 using electric knife
           Cut a piece of fabric  15” x  30”     
     Finish 15” raw edges by folding over twice and stitching edge., 
     Fold with right sides together so that you have a rectangle 15”x12.5”, there will be a significant overlap   
S   Stitch the 12.5 inch sides together with a ¼ inch seam allowance.
      Turn inside out, and stuff pillow inside.

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