REAL MAN TRUCKWORKS & SURVIVAL

TOOLS, CONSTRUCTION, ALTERNATIVE ENERGY => What are you building? => Topic started by: Flyin6 on June 22, 2018, 10:52:41 AM

Title: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 10:52:41 AM
This will be a project thread on how to build Adirondack chairs.

I did not invent these plans but sourced them from a talented lady who has a web site, "Skip to my Lou"

The classic and simple outdoorsy chairs are beautiful and very comfortable in my opinion and my plans have always been to make a bunch of them and set them about my farm and primary home. They make great house warming gifts as well and possible heirlooms for the kids/grandkids.

Here is a link to the website and free download of the plans for the chairs:

https://www.skiptomylou.org/free-adirondack-chair-plan-printable/
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 10:53:49 AM
Get the download, transfer it to a thumb drive and drive over to your nearby staples to have them printed on two 24" X 36" sheets
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 10:54:30 AM
Cut out the 12 patterns for the various pieces of the chair
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 10:56:48 AM
You can simply trace that out onto your materials or go one step further like I did.

My concept is to make many of these throughout the years as gifts, so I transferred the patterns onto some 1/8" masonite. I used some spray adhesive to permanently attach the paper, then cut out the sections on a jig saw
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 10:59:06 AM
Now this the cool part that both craftsmen and hippies alike will appreciate. Since I own a sawmill machine, I selected some Cedar trees, dropped them, then cut them up on the sawmill into 1" thick boards. I then further processed those rough cut boards squaring them up on a table saw
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 11:03:46 AM
I decided to start by building two of these chairs. The plans which are well laid out use boards from three different thicknesses. "Lou" created her original design using 5/4" X 6" Pressure Treated Deck Boards from Lowes. She was in fact contracted by Lowes to design something interesting for the back yard by that corporation some time ago and won some competition with her elegant design.

I'll publish the widths in a bit, sorry, but I don't have the numbers at the moment.

I ripped my rough sawn timber into the proper widths and cut out all the blanks for the two chairs:
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 11:06:40 AM
At this point, I did not have all the various archs and curves cut out, but it was time to plane or sand the boards to get them to a useable thickness.

Not a part of this build process, but I purchased a DeWalt Planner to take care of that task. This is one terrific machine, which I constructed a hasty table for.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 11:08:41 AM
This particular machine runs at two speeds. The low speed makes a smooth cut that, frankly leaves a board which needs no sanding at all. The higher speed creates furniture grade cuts, which seem unnecessary in this material. Here is my first cut:
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 11:10:05 AM
After planing all pieces on both sides, here is the finished pieces ready for the schroll cuts:

This wood is absolutely beautiful!
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 11:10:38 AM
I completely love this new machine!
Title: Re: Adirondack Chair Project
Post by: Bob Smith on June 22, 2018, 11:23:17 AM
That wood should turn out some really nice looking chairs. Like your style for sure.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 11:25:05 AM
That wood should turn out some really nice looking chairs. Like your style for sure.
I am shocked at how beautiful that wood actually is! And to think these things are thought of as junk trees! Around here people burn them or cut them up for fence boards!
Title: Re: Adirondack Chair Project
Post by: stlaser on June 22, 2018, 11:41:47 AM
Any consideration taken to drying the lumber?
Title: Re: Adirondack Chair Project
Post by: Tommy13 on June 22, 2018, 11:59:31 AM
Thanks for posting this up Don.  I'm considering tackling this exact project.  We need some chairs for the new casa.
Title: Re: Adirondack Chair Project
Post by: cruizng on June 22, 2018, 01:33:07 PM
I completely love this new machine!

I give two thumbs up for that planer as well. In NJ we had a cedar back deck that was 26' X 90'. Spanned the entire length of the house. I pulled up all of the cedar board which were nailed down and planed the underside. Then screwed them back down. Most of the boards were at least 24'. Had to replace some of the boards but it turned out nice. That planer paid for itself many times over. Didn't have to sand anything.  :likebutton:
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 02:42:13 PM
Any consideration taken to drying the lumber?
About half of the boards were cut over a year ago. The others from logs that were sitting around for a couple weeks.
I'd like to dry the wood, but after thinking about it, these chairs will stay outside forever, so i just decided to run with it.
Title: Re: Adirondack Chair Project
Post by: stlaser on June 22, 2018, 04:06:45 PM
Copy, looks good!  :likebutton:
Title: Re: Adirondack Chair Project
Post by: Bigdave_185 on June 22, 2018, 05:56:07 PM
Wanna send me some planks in the mail so I can line my closets with it?


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Title: Re: Adirondack Chair Project
Post by: KensAuto on June 22, 2018, 06:22:44 PM
I bet your shop smells great right now!
Always loved the smell and look of cedar. I bet you feel great using wood from your land, milled in your machine, and eventually wood that you will rest your body on, sore from all of the hard work!
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 22, 2018, 06:45:44 PM
I bet your shop smells great right now!
Always loved the smell and look of cedar. I bet you feel great using wood from your land, milled in your machine, and eventually wood that you will rest your body on, sore from all of the hard work!
I do love it

It seems so cool to just process my own stuff into other stuff I and others can use.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 10:59:40 AM
Next, I spent some personal time with my saber saw, a 20 volt DeWalt unit which did a great job in this soft cedar wood
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:01:50 AM
The templates I created has the drill points for the various holes that are needed. I drilled 1/8" holes at all points, then enlarged the bolt holes to 5/16" using a forstner bit drilled from each side to prevent any unwanted breakout of the wood
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:05:41 AM
I am using 2" X 5/16" carriage bolts, washer and nuts. With my thicker than recommended pieces the bolts were a bit too short. I will increase the bolts to 2.5" for the next evolution. These two chairs are my test build set. I just wanted to work through all the processes to streamline the process. Next I will build four of these chairs as house warming gifts for the girls, but in the future, I plan to build many of these, mostly as gifts for peeps. I'll have this whole thing figured out by the end of the day...
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:08:43 AM
With all the holes falling within spec (Aligning well) I assembled all four legs
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:09:13 AM
And then the front cross piece
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:10:14 AM
Followed by the lower back upright support
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:11:17 AM
The front arm rest supports go on next using the two predrilled holes in the front legs
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:13:00 AM
On top of that, I screwed the arm rests in to the upright with one screw only to facilitate later on fine positioning of the backrest
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 11:15:09 AM
The only technically challenging part of this build is the required 30 degree angle cuts of the top backrest attachment point and the lower first seat board. I used a band saw set at the 30 degree angle and did A LOT of cutting!
Title: Re: Adirondack Chair Project
Post by: cudakidd53 on June 25, 2018, 01:30:33 PM
Looking good there Don!
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 04:04:21 PM
Next I had to create a 30 degree angle on the top cross piece which captures the uprights. There are a variety of ways to do this. A belt sander makes a pretty easy job of it, since absolute precision is not required, I think it is a great expedient.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 04:06:22 PM
That piece is supposed to get secured to the rear of the arm rests with carriage bolts, but my 2" long units proved to be too short, so I temporarily just screwed the pieces together until I can secure some 2.5" bolts.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 04:08:44 PM
Then a guide board was clamped to the bottom of the lower rear brace so the back rest boards can be placed for measurement and checking. Everything came out just on the mark so after some squaring, it was on to securing those boards
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 04:10:26 PM
Although the plans did not call for it, I added a brace across the back of the center three boards to keep deflection to a minimum
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 04:12:23 PM
Then the angle cut curved piece which was a bit challenging to create was sanded and screwed down. THis piece is the base from which you add the rest of the seat pieces, so attention needs to be paid to getting this piece square.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 04:13:36 PM
Then five of the seat pieces were sanded, spaced then screwed down to complete the seat part of the chair.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 04:18:22 PM
I added an additional screw to the armrest, catching the supports and really stiffening up the whole chair.

So this is it, ready to provide years of comfortable shade seating or in the case of these chairs, on to finishing where some protective something will be sprayed on accumulating several coats before final deployment to the forward area reconnaissance mission (FARM)
Title: Re: Adirondack Chair Project
Post by: Tommy13 on June 25, 2018, 05:05:36 PM
Looks great Chief!  The only part I think I'll have any issue with is the 30 degree cuts.  Maybe a bandsaw is in order?  :popcorn:
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 05:41:19 PM
Looks great Chief!  The only part I think I'll have any issue with is the 30 degree cuts.  Maybe a bandsaw is in order?  :popcorn:
Either that or a belt sander, aggressive belt and a steady hand
Title: Re: Adirondack Chair Project
Post by: stlaser on June 25, 2018, 06:46:51 PM
I just had a vision of these chairs being delivered, sweet tea and the hay fields overgrown and new cedar trees sprouting up everywhere over running the place. Probably some used appliances on a front porch even...  :popcorn:

Somebody falls asleep and no work ever gets accomplished again
Title: Re: Adirondack Chair Project
Post by: cudakidd53 on June 25, 2018, 07:32:42 PM
^^^ That’s the point of the chairs - RELAXING - gotta grow more cedars to build more chairs anyway.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 25, 2018, 09:12:14 PM
I just had a vision of these chairs being delivered, sweet tea and the hay fields overgrown and new cedar trees sprouting up everywhere over running the place. Probably some used appliances on a front porch even...  :popcorn:

Somebody falls asleep and no work ever gets accomplished again

That's not a vision

That's a nightmare!
Title: Re: Adirondack Chair Project
Post by: Bigdave_185 on June 25, 2018, 10:54:04 PM
When can we start placing orders for these? Mr Massproduction set up.   I’ll take two


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Title: Re: Adirondack Chair Project
Post by: JR on June 26, 2018, 01:18:14 AM
Looks great and comfy!

Always wanted a planer, just can't really justify it.

Mass production, hello pre-rangers,,,,,,,,,
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 26, 2018, 10:48:13 AM
When can we start placing orders for these? Mr Massproduction set up.   I’ll take two


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I knew this was going to happen!

So I am in the midst of making four more...for the girls...two each, both are moving next month into their new houses...

So last night, wife asks if I'll make two for a friend who is helping us do a wedding...
Title: Re: Adirondack Chair Project
Post by: stlaser on June 26, 2018, 10:59:59 AM
They are nice looking Don, Quality piece for sure.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 26, 2018, 11:12:34 AM
They are nice looking Don, Quality piece for sure.
Thank Ya!
Title: Re: Adirondack Chair Project
Post by: JR on June 26, 2018, 01:04:17 PM
Bench in a box kit!!
Title: Re: Adirondack Chair Project
Post by: moto123 on June 26, 2018, 01:24:24 PM
So .... did you sit in it?  My issue is typically the backrest is too short and my head lands halfway on the top board.  Building from scratch it would be easy to lengthen those pieces by a couple inches.  Just wasn't sure if that was necessary.
Title: Re: Adirondack Chair Project
Post by: KensAuto on June 26, 2018, 01:31:53 PM
Me likey!

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Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 26, 2018, 04:32:46 PM
So .... did you sit in it?  My issue is typically the backrest is too short and my head lands halfway on the top board.  Building from scratch it would be easy to lengthen those pieces by a couple inches.  Just wasn't sure if that was necessary.
I did sit in them. I think the position is perfect. Having said that, the head board could be taller, but I'm a long guy so what fits me may seem big for most folks, especially a lady.
Title: Re: Adirondack Chair Project
Post by: Bigdave_185 on June 26, 2018, 09:41:18 PM
Well when do we get a price to ship these beautiful thing,  we can talk you right out of retirement


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Title: Re: Adirondack Chair Project
Post by: Bob Smith on June 26, 2018, 10:10:13 PM

Yup for sure...I will take at least two and more likely four. How much for shipping and a small amount for you to put into the box on Sunday.


Used to have the flatbed truck show up with outdoor furniture stacked to the hilt looking for a sale. These are by far way above those things.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 26, 2018, 10:34:24 PM
I just sprayed one with four coats of Hellman's Spar Urethane in satin to give one a protective coating. It is still wet from all the urethane so no pic yet. I chose a satin so the finish is more or less invisible just to see how it looks in a more "natural" finish. I was thinking of doing the other one in a gloss spar urethane, then see which one looks the more tasteful. I can say that while the stuff was wet and glossy, that wood was really popping. The satin darkened the wood a little bit, but at this point, that's all I know for sure.
Title: Re: Adirondack Chair Project
Post by: JR on June 27, 2018, 12:13:38 AM
Now what is the chance of seeing this today at my local ACE store.

I am sure the quality is know where near what BD has made.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 27, 2018, 11:41:59 AM
^^^ Made in China...It has to be a quality product!
Title: Re: Adirondack Chair Project
Post by: cudakidd53 on June 27, 2018, 01:13:43 PM
 Don I think you need to petition the government for a tariff to protect your sales!  Right in China, making all those little kids do all that sweat shop labor..... bet you they don’t even call them pre-Rangers there!
Title: Re: Adirondack Chair Project
Post by: JR on June 27, 2018, 01:59:19 PM
I make no comparison cept the name. I would rather have a pre ranger chair than a commie chair.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 27, 2018, 04:54:22 PM
I make no comparison cept the name. I would rather have a pre ranger chair than a commie chair.
And the pre-Rangers helped in cutting the logs up on the saw mill

Update: Started on the next four. Have about 25% of the pieces cut, but am out of cedar. Rain every couple days is making it tough to get down there to cut more lumber, and when I finally do it's 90+ and high humidity...

THe satin finish on the first "Test" chair turned out so-so. I don't think it's nearly as good as it can get, so I am going to revisit this. Plan is to lightly sand the chair down and spray it again. I used two rattle cans of the spar Urethane, but the spray seemed really light and watery to me. I am thinking of getting the stuff in gallons and spray it with a real sprayer so I can accumulate some thickness to the material.

So stand by for a stand by!
Title: Re: Adirondack Chair Project
Post by: JR on June 27, 2018, 05:13:23 PM
Look at teak oil.
Title: Re: Adirondack Chair Project
Post by: Bob Smith on June 27, 2018, 05:21:56 PM
When you start sealing them be sure the wood is dry or it will end up being a mess at best.
Title: Re: Adirondack Chair Project
Post by: Bigdave_185 on June 28, 2018, 01:19:07 AM
The airless would for sure put on a much thicker coat and a longer lasting finish for sure.  Don’t buy cheap lacquer to spray and it will treat you well.  Just buy a five gallon and handle busines


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Title: Re: Adirondack Chair Project
Post by: TexasRedNeck on June 28, 2018, 07:10:10 AM
Nice work Don. Good looking and durable as long as you don’t run over it with Spud.

I like JRs idea. Natural oil finish


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Title: Re: Adirondack Chair Project
Post by: stlaser on June 28, 2018, 07:30:29 AM
Nice work Don. Good looking and durable as long as you don’t run over it with Spud.

I like JRs idea. Natural oil finish


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I agree ^^^^^^^^ lacquer will peel eventually I think.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 28, 2018, 08:28:41 PM
The airless would for sure put on a much thicker coat and a longer lasting finish for sure.  Don’t buy cheap lacquer to spray and it will treat you well.  Just buy a five gallon and handle busines


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Airless was on my shopping list for today.

Glad I didn't purchase yet

SLOWES and HD had esentially the same 1/2 HP unit for $299 (-10% mil discount) = About $260 + Tax

HF had a unit with all the same specs for $214

After coming home and checking the mail, that HF unit is on sale for $169.99

The girl at the cash register gives me a one year warranty for fifty cents! Yes you heard that right, and a two year for $8.

So I think I'll pick up the HF unit with a 2 year warranty and just trade it out whenever it fails, if at all.

First up, I'll spray these chairs with the good stuff, then take it down farmside and put a shiny coat on Chief. That will take 6-7 gallons or more so it should really tax the little sprayer. If it kills it, so be it, I'll pick up a new one.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 28, 2018, 08:30:50 PM
Nice work Don. Good looking and durable as long as you don’t run over it with Spud.

I like JRs idea. Natural oil finish


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I agree ^^^^^^^^ lacquer will peel eventually I think.
Who said anything about spraying Lacquer?

I use Hellmans spar urethane, which is made for boats and severe outdoors usage...
Title: Re: Adirondack Chair Project
Post by: Flyin6 on June 28, 2018, 08:31:14 PM
Nice work Don. Good looking and durable as long as you don’t run over it with Spud.

I like JRs idea. Natural oil finish


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Ya...Copy!
Title: Re: Adirondack Chair Project
Post by: Bigdave_185 on June 29, 2018, 12:40:44 AM
I spray it when ever I can, love the smell


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Title: Re: Adirondack Chair Project
Post by: stlaser on June 29, 2018, 01:06:19 AM
I spray it when ever I can, love the smell


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& now we know why you have to be 18 to buy spray paint at waltuky  :tongue:
Title: Re: Adirondack Chair Project
Post by: stlaser on July 21, 2018, 11:08:42 AM
I sent these to Don yesterday for reference if anything to know his market as he gives these away and how great a gift they actually are in fact. We were up at Cheyenne Frontier Days, granted it's a fair and price is negotiable I'm sure. However I think these are of similar quality to what Don is building. The lumber looked to be at minimum 1 inch thick throughout.

(https://i.imgur.com/1pKWZWz.jpg)

(https://i.imgur.com/Efftskv.jpg)
Title: Re: Adirondack Chair Project
Post by: Flyin6 on July 21, 2018, 11:13:13 AM
And publically, I thank you Shawn for sending me that pic

I really like the backrest. It has a pedal like floral quality to it. Would take more time on the bandsaw, but is so easy on the eye and natural.

And my boards start at 1" thickness, then after a pass on each side in the planer are 3/4" approx.

I wanted to keep the chair lighter, and Eastern Cedar already is, but the thicker boards do look good.
Title: Re: Adirondack Chair Project
Post by: stlaser on July 21, 2018, 11:16:12 AM
 :likebutton:

I didn't think to pick one up, here they need to be heavy to resist those Wyoming winds that blow thru.....
Title: Re: Adirondack Chair Project
Post by: Flyin6 on July 21, 2018, 11:21:15 AM
:likebutton:

I didn't think to pick one up, here they need to be heavy to resist those Wyoming winds that blow thru.....
Makes sense!
Title: Re: Adirondack Chair Project
Post by: TexasRedNeck on July 22, 2018, 07:35:15 AM
Put the Santa Fe name on it and it’s worth double!!


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Title: Re: Adirondack Chair Project
Post by: Farmer Jon on July 22, 2018, 09:22:33 AM
Now what is the chance of seeing this today at my local ACE store.

I am sure the quality is know where near what BD has made.

You could use it as a pattern. Shure Dons pattern is free but you have to have it printed out on paper. This would be a hard template.
Title: Re: Adirondack Chair Project
Post by: Flyin6 on July 22, 2018, 12:18:43 PM
Now what is the chance of seeing this today at my local ACE store.

I am sure the quality is know where near what BD has made.

You could use it as a pattern. Shure Dons pattern is free but you have to have it printed out on paper. This would be a hard template.
I already plan to change up the back  boards. I want them to be a bit taller and liking the shape, come up with something uniquely mine...
Title: Re: Adirondack Chair Project
Post by: Flyin6 on September 30, 2018, 02:26:15 PM
Well, I gave the first two away as a house warming present. The new owners just loved them, really did. They were occupied the whole evening during a house warming party.

So next up is to complete the four in production, then design my rocker, then the glider love seat adirondack.
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