- 1). Begin by cutting the seat slats out with the jigsaw. You will need about 10 slats, each measuring 3 inches wide by 30 inches long. Also use the jigsaw to cut out the seat side supports, which will be 3 inches wide by 28 inches long and rounded at both ends.
- 2). Place the side supports perpendicular to either end of one of the slats and screw the slat down tight with the wood screws. Form the seat by laying the rest of the slats down parallel with the first slat and butting them up against one another. Screw them all down tight and make sure to cover one of the rounded edges with slats as well, but leave the other rounded edge open, as this will serve as your base later on.
- 3). Cut out the back slats using the jigsaw. You need seven slats that measure 3 inches wide by 40 inches long. Now is also a good time to cut out two front legs (3 inches wide by 23.75 inches tall) and the pieces for the back brace (three slats 2 inches by 30 inches) using the jigsaw. Sand all of the pieces smooth with the sandpaper before continuing.
- 4). Attach two of the back braces to the round side of the seat without slats installed--the "base"--using the lag bolts. Connect the top of the two braces with the third slat you cut out for the back brace. Now attach the back slats by screwing them into the back brace crosspiece and the base of your chair. Butt each of the back slats up against each other, parallel along their long edges, and screw down tight at the back brace crosspiece and the base.
- 5). Install the two front legs, putting the seat at a 35- to 45-degree angle to the chair back. Cut out two armrests that measure 3 by 24 inches and connect the front legs with the back legs by screwing the armrests into the tops of the front legs and the sides of the back brace.
- 6). Sand the entire chair down one more time to make sure it is smooth. When you are sure the chair is smooth, apply a thin layer of lacquer and allow it to dry to tacky. Sand the surface of the chair again and then reapply the lacquer. Do this two or three more times until you are sure the entire chair has been sealed properly and then allow it to dry for 48 hours before using outside.
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