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How to build an outdoor chair with Ryobi

Outdoor timber chair on a deck with cushions and seat pad.

Overview

You’ll have a huge sense of accomplishment and the perfect place to relax once you’ve made this outdoor chair yourself (with a little help from Ryobi). Making an outdoor chair is the perfect weekend project and easy if you follow these handy steps.

Safety tip: Always wear the appropriate safety equipment (safety glasses, ear muffs, gloves and mask, for example) and always follow the instructions for the product or equipment.

Steps

1Cut the base of the chair

First, grab a piece of project panel, then measure out the base of the chair. Cut a 1200mm x 600mm rectangle using your Ryobi 18V ONE+ HP™ Brushless Circular Saw - the perfect tool for the job.
Person using a saw and level to cut the base of the chair.

2Cut the chair arms

Once you have the base, it’s time to cut the arms of the chair. Cut two 600mm x 350mm pieces of project panel. Then, along the bottom of the 600mm sides on both arms, cut a 10-degree angle using a circular saw.
Person using a saw and level to cut the base of chair.

3Curve the chair arms

To create a sleek, modern design, curve the tops of the arms. To measure a curve, grab a piece of string, tape it down in the centre, attach a pencil to the other end and draw a curve. We’ve gone for a curve with a wider radius. The curve should be made on the diagonal corner to the 10-degree angle.
Person marking timber base with a pencil.

4Cut the angle for the backrest

To create a reclined look and comfortable angle for chilling, you’ll need to cut an angle on the chair sides where the base, back and arm panels meet. To do this, mark a 10-degree angle from the top left of the panel to the bottom.

With all of your measurements taken and lines drawn, use a Ryobi 18Volt ONE+ HP™ Brushless Jigsaw (remember to double check your measurements before cutting). You’ll end up with curved corner diagonal to the 10-degree angle for the recline on the chair arm. Once you have one arm piece complete, use it to trace on the second panel, then cut that one too.

Person cutting the angle for the backrest.

5Pre-drill holes for screws

To attach the arms, you’ll need to use your Ryobi 18V ONE+ Drill Driver. Pre-drill 4mm holes in the base to allow you to screw on the sides without splitting the timber - space the holes approximately 100mm apart. With the holes pre-drilled, go ahead and screw the sides into the base. Once sides have been attached, the structure should resemble a ‘v’ shape.
Person pre-drilling holes for screws in timber board.

6Mark and cut the back panel

Once the sides and base are attached, lay this over the remaining piece of project panel. Trace an outline of this shape along the outside onto the panel as this will make sure the back panel is the correct size for both the height and length between the arms. Use your Ryobi 18V ONE+ HP™ Brushless Circular Saw to cut along these lines and then place on the chair to check that it fits flush.
Person cutting through back panel with circular saw and level next to it.

7Attach the backing board

The last thing to do here is pre-drill 4mm holes (approximately 100mm apart) into the backboard and then screw it into place.
A person drilling into the timber bench with a drill.

8Create the cross bench

Next, you’ll need to build a crossbench that attaches to the legs and base of the chair. This is to ensure the chair can support people sitting on it as it works to evenly distribute the weight.

To build this, start by cutting out two panels slightly shorter than the base of your chair and then cut a 45-degree angle to all ends. This is what you’ll attach the legs to.

A man drilling the timber legs to the cross bench with a drill.

9Cut chair legs and attach to cross piece

Then you can start measuring and cutting the legs. Make these are approximately 300mmm long, cut both ends on a parallel 45-degree angle. Remember to make sure all four legs are the same length so that your chair doesn’t have a wobble!

Pre-drill holes in the tops of each leg and then screw them into the cross piece using 8-gauge x 40mm stainless steel decking screws. Make sure they are flush and do this for each leg.

Person cutting timber chair legs with a mitre saw.

10Assemble legs, cross-bench and chair

Lastly, turn the chair upside down and screw the completed cross piece onto the base of the chair - be careful not to let any screws poke through to the other side.

And you’re all done, ready for a rest on your new outdoor chair! Now you can sit and ponder about what your next project could be…with Ryobi of course!

A person attaching the timber chair legs with a drill to the bench.

11Watch the full episode

For more renovation inspiration, watch Episode 2: House facade and garden renovation in our Make It Happen: The House Project series.
Health & Safety

Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.

When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.