Hey there, fellow DIY enthusiasts! Robert Kline here, and I’m excited to share a fantastic project that combines sustainability, cost-effectiveness, and of course, the joy of crafting. Today, we’re diving headfirst into building a sturdy, comfortable folding beach chair using recycled pallet wood. That’s right, those often-overlooked shipping marvels can be reborn as your perfect beach companion.
This project is inspired by the ingenious design of the “Becket Chair,” dreamed up by Instructables user jleslie48. It’s a testament to how a simple, clever design can yield impressive results, and I’m eager to guide you through each step, ensuring you can bask in the sun with your very own creation.
Gathering Your Materials and Tools
Before we embark on our woodworking adventure, let’s gather everything we’ll need. The beauty of this project is its simplicity, requiring minimal materials:
Materials:
- Pallet Wood: Source enough pallet wood to yield thirteen 1″x2″x14″ pieces for the spindles, four 2″x2″x26″ pieces for the supports (you can opt for 1″x2″x26″ if preferred), and one 1″x2″x12.5″ piece for the bottom back brace. Remember to carefully dismantle your pallets and remove any nails or staples.
- Wood Glue: Titlebond outdoor wood glue or a similar waterproof wood glue is recommended.
- 1 1/4″ Wood Screws
- Sandpaper
- Teak Oil
- Marine Varnish
Tools:
- Saw: A hand saw or circular saw will work for cutting the pallet wood.
- Drill: A drill with a screwdriver bit and a bit for pre-drilling screw holes.
- Measuring Tape
- Pencil
- Safety Glasses
Building the Jig: Your Key to Precision
While optional, I highly recommend taking the time to build a jig, just as jleslie48 did. A jig acts as a guide to ensure accuracy and consistency in your cuts and assembly. Don’t worry; it’s a straightforward process.
Creating the Jig:
- Base: Use a piece of scrap plywood or sturdy cardboard as the base for your jig.
- Spacers and Guides: Cut scraps of 1×2 lumber to create spacers and guides that will help you position the chair supports and spindles correctly.
- Assembly: Attach the spacers and guides to the base using wood glue. The exact placement will depend on the dimensions of your chair, so refer to jleslie48’s instructions and diagrams for guidance.
A simple jig helps ensure accurate assembly.
Constructing the Chair Back
- Positioning the Supports: Place two of your 2×2 supports onto the jig, using the spacers to ensure they are properly aligned.
- Attaching the Spindles: Take one of the 1×2 spindles and position it horizontally across the top of the supports. Pre-drill screw holes to prevent the wood from splitting, and then attach the spindle to the supports using wood screws and wood glue.
- Spacing the Spindles: Continue attaching the remaining spindles, using spacers to maintain even spacing between each one.
- Adding Cross Supports: Measure and cut two additional spindles to act as cross supports. These will be attached horizontally to the supports, providing additional stability. Refer to the diagrams for the exact placement of the cross supports.
Assembling the Chair Seat
The chair seat is assembled similarly to the back:
- Spindle Placement: Place the supports on the jig, using spacers to ensure the seat spindles will align correctly with the back spindles.
- Attaching Spindles: Attach the spindles to the supports using the same method as before: pre-drilling, gluing, and screwing.
- Bottom Cross Support: Attach the 1x2x12.5″ piece as a cross support at the bottom of the seat supports.
Finishing Touches
- Sanding: Thoroughly sand all surfaces of the chair to remove any rough edges and splinters. Pay attention to rounding over the edges for a more comfortable feel.
- Sealing and Protecting: Apply a coat of teak oil to all surfaces, allowing it to penetrate the wood. Once dry, apply a coat of marine varnish. Allow to dry completely. Repeat the varnish application several times for a durable finish.
Enjoy Your Creation!
Congratulations! You’ve successfully transformed discarded pallet wood into a functional and stylish beach chair. Now, sit back, relax, and take pride in your craftsmanship as you soak up the sun.
This project is a fantastic example of how a little creativity and effort can yield impressive results. Don’t forget to check out Robert Kline Art for more inspiring DIY projects and craft ideas. We’d love to see photos of your finished beach chairs, so feel free to share them in the comments below. Happy crafting!