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Fit the legs to the seat of the adirondack chair, as shown in the diagram. Drill pilot holes and insert 1 1/4″ screws to lock the legs to the seat of the chair. Add glue to the joints and align the edges. .
Now prepare the upper rear crosspiece. Prepare the part by using the pattern provided on page 41 for the inside curve. Note the inside cut is not only curved, but is cut at a 30° angle as well. Tilt the band saw table appropriately then saw the curve. Then return the band saw table to 0°, or square, and cut the ends. Sand the edges.
What is not apparent in any of these shots is long grain, thick strips of teak, glued and screwed to the bottom of all ground contact pieces of the chair. Cedar is quite poor for scraping or dropping damage, and sucks up water like a camel to water, but is otherwise fine. i.e. warm and light and soft. A real class act with finer details possible could be achieved in mahogany or ipe. chair adirondack cedar westport 99 1
When all the plugs were glued in and trimmed, I gave my chair a good sanding (#150 grit). The relatively soft cypress sands easily. While sanding, I made sure any sharp edges were eased.
As for the size of the chair, it’s slightly smaller then the King Size Highwood brand. Which is probably to be expected having a smaller weight capacity of 300 pounds. The seat itself is just under 21″ wide and sits 14 inches from the ground. As for the back of the chair it’s also just shorter at 36.9 inches in height. Assembly is somewhat easier, but do note: Don’t over tighten the screws or you could damage the ends,or even worse crack the slat. Just go gently if using a drill.
Eucalyptus is a hardwood massively cultivated in Australia and recently in South America. It is relatively affordable than most other imported hardwoods.
Ipe wood lasts a good 3-5 decades without any finish or treatment and even much longer when treated, finished, and maintained periodically.
But you are also going to see those with upright or straight backs. You need to make a decision which chair would work for you. Which back curvature will benefit you most?
Now install the back slats. To get the right look, proper spacing of the slats is important. Start with the center slat, placing it dead center in the back. I used four screws for each back slat, inserting one in the bottom, then made sure the top was positioned properly, then I secured it with three more. Be careful drilling the screw holes and countersink for the upper crosspiece as these must be done on an angle, drilling straight into the crosspiece, but at an angle to the back slat.
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Your chairs turned out great. Building them are a lot of work but it’s so worth it. They look great by your workshop!
Just picture one or two of these Cambridge Casual Lyon Wood Outdoor Adirondack Chairs ($189) on your deck or in your backyard. The chair comes with an ottoman for extra comfort when you're in the mood for it.
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All screw holes should be pre-drilled for a couple reasons; to prevent splitting by drilling a pilot hole and to countersink sufficiently to accept a wood plug later. The plug not only helps the appearance of the chair, but will also add to the chair’s durability. We used a bit that drilled the hole and counterbored for the plug in the same operation.