How To Make A Deckchair - Hand Tool Version

Before we start

We bought our timber machined and then ripped it down using a table saw. A good timber yard would do this for you if you supplied the cutting list. Alternatively you could use a jigsaw. If you already have machines in your workshop, why not try our machine version of How To Make a Deckchair.

Step 1

Mark out and then cut each piece to length using a crosscut saw. We used a Japanese Crosscut Saw. Each piece should be 20mm thick.

Step 2

Rip down timber pieces to size with a rip saw. We used a Japanese Rip Saw.

Step 3

Using a hand plane clean up edges and faces of the timber.

Step 4

Then, using a crosscut saw and a bench hook, trim the pieces to length.

Step 5

Mark out holes with marking gauge to accept 20mm dowels as per drawing; use a bradawl to mark the centre.

Step 6

Using a power drill and a 20mm forstner bit, drill all the holes to half the depth of the timber.

Step 7

Mark out 6mm holes as per the drawing.

Step 8

First use a 12mm forstner bit and countersink the marked holes with a power drill to the depth of the shoulder of the drill bit.

Step 9

Replace the forstner bit with a 6mm bit and drill through.

Step 10

Using a block plane soften the edges of all pieces.

Step 11

Take the two medium lengths and mark out reclining slots - three slots at 110mm, 210mm and 310mm intervals from the end.

Step 12

Using the 20mm forstner bit, drill the beginnings of the slots.

Step 13

Then, using a protractor set at 15°, mark out the remaining parts of the slots.

Step 14

Using a fine blade Japanese saw, cut out the rest of the support notches.

Step 15

Sand back all rough edges of the slots using a piece of abrasive wrapped around a section of dowel.

Step 16

Cut all dowel to length with a saw and a bench hook.

Step 17

Next, cut dowels at 2 x 450mm, 2 x 490mm and 1 x 525mm. Then finish all parts with an outdoor finishing oil.

Step 18

Dry fit together making sure all parts fit correctly.

Step 19

Assemble deckchair frame, glue the two frames and clamp together.

Step 20

Using the dowel, stainless steel nuts, bolts and washers, assemble the frames together.

Step 21

Lay deckchair frame flat on a workbench and cut fabric to length.

Step 22

Using upholstery tacks attach the fabric to the frame.