This step by step diy project is about outdoor sectional chair plans. I have designed this outdoor chair to match the rest of the sectional projects I have on the site: the sofa and the corner unit. This chair only requires 1x4s and 1x3s so you can get the job done in just one day without much effort. Make sure you buy the cushions before building the chair so you can make adjustments. Take a look over the rest of my woodworking plans, if you want to get more building inspiration.
When buying the lumber, you should select the planks with great care, making sure they are straight and without any visible flaws (cracks, knots, twists, decay). Investing in cedar or other weather resistant lumber is a good idea, as it will pay off on the long run. Use a spirit level to plumb and align the components, before inserting the galvanized screws, otherwise the project won’t have a symmetrical look. If you have all the materials and tools required for the project, you could get the job done in about a day. See all my Premium Plans HERE.
Projects made from these plans
Outdoor Sectional – Chair Plans
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- A – 2 pieces of 1×4 lumber – 24″ long, 4 pieces – 26″ long FRAME
- B – 2 pieces of 1×4 lumber – 27 1/2″ long, 7 pieces – 17″ long SEAT
- C – 2 pieces of 1×4 lumber – 20″ long, 2 pieces – 28 1/4″ long LEGS
- D – 1 piece of 1×4 lumber – 24″ long, 1 piece of 1×3 lumber – 25 1/2″ long BACKREST SUPPORT
- E – 2 pieces of 1×3 lumber – 27 1/2″ long ARMRESTS
- 5 pieces of 1×4 lumber – 8′
- 1 piece of 1×3 lumber – 8′
- 100 pieces of 1 1/4″ pocket screws
- 100 pieces of 1 1/4″ screws
- 2″ brad nails
- wood glue, stain/paint
- wood filler
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Building an outdoor sectional chair
The first step of the project is to build the frame for the chair from 1x4s. Cut the components at the right dimensions and drill pocket holes at both ends of the 26″ long components. Align the edges with attention, making sure the corners are square and insert 1 1/4″ pocket screws. Add waterproof glue to the joints for more support.
Next, build the seat for the chair. Cut the components from 1×4 lumber and drill pocket holes, as shown in the diagram. Place the slats equally-spaced and insert 1 1/4″ pocket screws to get the job done. Place a piece of 1/2″ plywood between the slats to create even gaps.
Fit the seat to the frame and align the edges with attention. Use 2″ brad nails to secure the seat into place tightly, making sure you leave no gaps between the components.
Build the legs from 1×4 lumber. As you can easily notice in the diagram, you need to make and angle cut to the back leg. Smooth the edges with sandpaper for a professional manner.
Attach the legs to the frame of the chair, as shown in the free plans. Drill pilot holes through the legs and insert 1 1/2″ screws into the seat frame. Make sure the corners are square for a professional result.
Fit a 1×4 slat to the backrest. Drill pocket holes at both ends of the slat and secure it to the back legs with 1 1/4″ pocket screws. In addition, use 2″ brad nails to secure the 1×3 slat to the top of the back legs.
Build the armrests from 1×3 lumber. Make a notch to the slats, as shown in the diagram, using a saw. Smooth the edges thoroughly.
Fit the armrests to the chair and secure them into place with waterproof glue and 2″ brad nails. Make sure you align everything with attention before inserting the nails.
Last but not least, you need to take care of the finishing touches. Fill the holes with wood plugs and with wood putty. Smooth the surface with 120-220 grit sandpaper. Apply a few coats of stain or paint to enhance the look of the components and to protect them from the elements.
I design this chair to complete the rest of the outdoor sectional projects I have designed. Fit the cushions and then enjoy your new project with your friends and family. If you build this, I would love to see your project.
This woodworking project was about free outdoor sectional plans. If you want to see more outdoor plans, check out the rest of our step by step projects and follow the instructions to obtain a professional result.