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Designed for lounging on passenger ships, deck chairs were made to be folded up and packed away in bad weather.
Before You Begin
Step 1: Cut Wood to Length
Step 2: Mark the Housings
Step 3: Chisel Out the Housings
Step 4: Rip the Crosspieces
Step 5: Notch Out Frame and Legs
Step 6: Make Frame A
Step 7: Make Frame B
Step 8: Pivot Frames
Step 9: Lay Out the Angle Set-Out for Frame C
Step 10: Stub Mortise and Tenon
Step 11: Assemble Frame C
Step 12: Attach Adjustment Frame
Step 13: Make the Sling
Step 14: Finish the Chairs
Written by Frank Gardner
For this project, select straight, knot-free, tight-grained wood, from pine to teak or one of many hardwoods. For longevity and strength, we used 3/4-in. x 1 5/8-in. ipe, a hardwood decking wood with rounded edges on all sides which reduced the amount of sanding.
Clamp the legs of frame A and mark the housing joints (see diagram below). Set a combination square at 3/4-in. and mark the depth on both sides. The gap between the pair of housings at the top is 3/8-in. Repeat for frame B, but at the opposite end.
Set the sliding compound miter saw to 3/4-in. depth and make close relief cuts between the set-out lines. Keep legs of frames A and B clamped together. Use a sharp 1-in. chisel to clean the housings. Sand to level and finish housing joints base.
Use a table saw or a circular saw with an edge guide to rip each of the cross pieces for frames A, B and C to a width of 1 1/8-in. If using a table saw, use the push stick for safety. Sand all of the crosspieces, rounding the edges.
Mark out the notches in the legs of frame B. Clamp each leg securely to a bench and cut out using a jigsaw. Make the square cut first then finish each notch by making the angled cut. Sand all cut edges and surfaces.
Check crosspieces fit housings. Mark center of crosspiece ends then drill a 5/64-in. pilot through to the housing. Remove crosspieces and drill a 5/32-in. clearance hole through the crosspiece to prevent splitting. Glue and fix with #6 x 1 1/2-in. stainless steel screws.
Use internal width of frame A to set the crosspiece length for frame B, allowing a 1/16-in. clearance between (see diagram in Step 5). Place frame B inside frame A and check for a neat but not overly tight fit. If tight, sand sides with a belt sander.
Clamp frames together. Mark the pivot point 13 3/4-in. from the lower end of frame A. Repeat on the other side. Drill a 1/4-in. hole through both legs on both sides. Use a 3/8-in. spade bit to recess holes on the inside of frame B by 1/8-in.
Mark position of adjustment frame crosspiece on the inside faces of the adjustment frame arms. Set angle at 35° to sit squarely in the notches. Mark the 3/8-in. x 3/4-in. mortise in the center of the set-out and tenons on crosspiece.
Wrap tape around a 5mm drill bit 13mm from the tip. Drill a series of 13mm deep holes inside mortise set-out lines. Clean out with a 19mm chisel. Cut and chisel to remove waste from four sides of the tenons then check for a tight fit.
Glue inside mortises and on cheeks and shoulders of tenons. Assemble frame C and hold with a sash clamp. Fix a brace at open end to keep arms parallel. Pre-drill and tap in a 3d finish nail on either edge of the arm into the tenon.
Clamp frames A and C together and drill two 1/4-in. diameter holes (see diagram in Step 9). Countersink holes on the inside face of frame A and recess 1/8-in. on the outside of frame C using a 3/8-in. spade bit. Join using #6 x 1 1/2-in. stainless steel bolts.
The chair is constructed so the fabric sling can be removed for storage or cleaning. Slings can be made from canvas, heavy-duty cotton or polyester, although fabric covers are only suitable for interior use. Pockets either end of the sling slide through the 3/8-in. gaps in frame A and B. Dowel inserts through the pockets. A padded flap flips over the top to hide the dowel and provide a headrest.
Test the adjustment frame slots into the pre-cut notches. Sand the frame, making sure edges are rounded where the sling contacts the wood to reduce wear. Apply two coats of exterior stain, paint or lacquer, lightly sanding between coats.
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