How to Build Your Own Customized Patio Chair: A Free DIY Building Plan

Patio Furniture

Designing and building your own patio furniture can have a lot of benefits, including the ability to create exactly what you want, save you money, and give you the satisfaction of completing a DIY project. The cost of patio furniture can vary greatly, depending on the quality of the furniture and the material used. Below I will share my free DIY patio chair building plan, so you can customize your outdoor furniture.

Materials

One of the most popular materials for outdoor furniture is wood, as it is sturdy and durable in various weather conditions. Cedar and redwood are both excellent choices because they are naturally resistant to rot and decay. Teak is another great option, but it tends to be more expensive. Be careful which wood you choose to use outdoors, not all will hold up in the elements.

Another popular material for outdoor furniture is metal, specifically aluminum and wrought iron. These materials are strong, durable, and rust-resistant. They’re also lightweight making them easy to move around when needed. I love my aluminum and metal outdoor furniture, and it is easy to freshen up each spring by simply adding a fresh coat of outdoor spray paint.

Lastly, there’s plastic or resin. This material is perfect for those wanting something low-maintenance and affordable. It’s lightweight, easy to clean, and resistant to sun damage.

Ultimately, the best material for your patio furniture will depend on your preferences and needs. Consider the climate in your area, the style you want to achieve, and your budget when making your decision.

Cost

Club patio chairs, like this one that I made, range from about $250-$1,000 each. Of course, this price range and actual costs may vary, depending on factors such as the size of the set, the brand, and where you purchase it from.

I was able to make this DIY patio chair for about $160 (including the cushion), and it’s solid and heavy duty.

DIY Patio Chair

Supplies Needed

• redwood 2 x 4 x 10 (x3)
• redwood 1.38 x 1.38 x 8 (x5)
• 1 1/4″ outdoor pocket hole screws
• 2 1/2″ outdoor pocket hole screws
• wood glue
• outdoor paint or stain
• outdoor patio cushions

Tools Needed

• table saw
• miter saw
• pocket hole jig
• measuring tape
• level
• power sander
• drill

Pocket Holes

Pocket holes are a woodworking technique that involves drilling angled holes into wood and then using screws to attach pieces together. One of the great things about pocket holes is their versatility – they can be used to create everything from simple picture frames to built-in cabinets.

By learning how to use pocket holes effectively, you can expand your DIY skills and create all sorts of projects for your home. And because pocket holes are relatively easy to learn and require minimal tools, they’re a great starting point for anyone interest in woodworking. Mastering the art of pocket hole joinery has taken my DIY projects to a whole new level. Check out my bathroom remodel and my home office remodel where I used pocket holes to build cabinets and a custom writing desk.

DIY Patio Chair Assembly

Square Edges

When creating a piece of furniture, the details matter. That’s why, for my chair, I decided to rip each piece of wood down to remove the rounded edges. I did this by removing 1/4″ from each side. This process involves using a table saw to trim off the excess material, resulting in a perfectly straight and uniform edge. While it may seem like a small step, taking the time to rip each piece of wood, can make a significant difference in the final appearance of your finished product.

Straight edges can give a more modern look to a piece of furniture. The sleek, clean lines that are achieved with straight edges, can create a minimalist and contemporary aesthetic that is popular in modern design. Straight edges also convey a sense of precision and accuracy, which can give a piece of furniture a more professional and polished look.

Ultimately, the choice of whether or not to use straight edges depends on the overall style and vision for the piece of furniture, as well as personal preference.

Pocket Holes and Wood Glue

Joining each piece of wood with pocket holes and wood glue is a popular method in woodworking. Pocket holes allow for a strong and secure joint that remains hidden from view, creating a sleek and professional look.

When pocket holes are combined with wood glue, the joint becomes even stronger. As the glue seeps into the fibers of the wood, it creates a chemical bond. This type of joint can resist any kind of movement or stress, making it a reliable choice for everything from furniture to cabinetry. Using wood glue also helps to fill any gaps between the pieces of wood, ensuring a flush and seamless joint.

Outdoor Paint or Stain

I used a solid tinted stain from Lowe’s because I didn’t want the red from the redwood visible through the stain. This was just personal preference.

Outdoor Seat Cushions

You can build this to fit any size cushion, but this is the one I used-

Cabana Stripe Outdoor Cushion

I have adapted the plan a little since I built this chair and this current plan will now fit this 2-piece set better. You can always adjust the measurements if you want to use these striped cushions.

2-piece Outdoor Cushion

Free Building Plan for DIY Patio Chair

Here is a free building plan that can be easily adapted to fit any size cushion. I hope that by providing this detailed and user-friendly plan, you will feel empowered to create a unique and personalized seating solution that perfectly fits your needs and style.

Whether you use small or large cushions, you can use this plan as a starting point and make adjustments, as necessary. This kind of flexibility is key for people who want to experiment with different materials or design elements. It can also help you save time and money by avoiding mistakes and rework (like I generally do:). I would love to see the furniture that you have created using this plan! Please tag me on Instagram or post a picture here!