How to Build a Pallet Adirondack Chair
Summer has arrived and the Adirondack chair on the pallet is screaming for relaxation. This is the best and most comfortable recliner. What if I told you right away how to make an Adirondack chair out of pallets, which are cheap and easy to get?
This is an exciting project, and the Adirondack Paddle Chair is a timeless addition to your outdoor furniture. You won’t be able to tell the difference with the wood bought in the shop, except that you already have the old, rustic look, which is desirable.
To complete this exciting project, here’s how to build an Adirondack Paddle Chair in 26 simple steps.
How to make an Adirondack chair from Pallets?
We have divided our Adirondack chair pallet plans into several steps so that they are easy to follow and you won’t lose your chair. It is best to read them all once before you start, then go back to step one and start.
What follows is the drawing of grids on the tree to cut out the shapes. Here’s a diagram to describe what we mean. You can customize each of these elements to your own taste and even skip some of them. We will provide all these details below when you come across them.
1. What you need
You need four good pallets, a hand saw, wood glue, screws, a crowbar or putty knife, wood putty, a drill, a hammer and a 3/8 shovel or Forstner bit for milling. If you have a puzzle, it is also useful to have a hand saw, but a hand saw can do it. Most, if not all, are already in place if you’re a trader.
2. Dismantling of pallets
It’s a lot easier than it looks. There are many tutorials you can see on YouTube. To facilitate this, first cut through the longitudinal members. Second: Use a hammer to drop the rope. Third: Disconnect the sign from the centre rail. That’s all I’m saying.
You can also buy pallets that have simply been disassembled. You don’t even need the technical details here. Use a claw hammer or crowbar and lift the tree where it is nailed. Then you have to hit the nails.
It’s as simple as that. You can also cut them and save as much wood as possible by cutting close to the nails.
3. Delimitation of seat cheeks
On the side of one of the 1×6 pieces of wood, 5.5 wide and 35 mm long, you have to draw a grid of blocks one centimeter by one centimeter. Now draw a smooth pattern with these 1/2 cubes to represent the spoon in which the person’s back will be.
You don’t have to do that part. This means a lot of time and effort for the project. Many people use flat chairs and don’t complain. It’s up to you. But after you’ve drawn a pattern on a string, you can wait to cut it and use it to draw exactly the same pattern on another person instead of drawing the grid twice.
You should choose the best pieces of wood for this part. Better said, I mean those with the least amount of splinters, cracks, water ingress, etc., and the least amount of water ingress. The only part you might want to cut out, even if you choose a flat seat, is the curved part at the front.
This gives your feet a smooth surface on the front seat, instead of the sharper edges digging into your hips behind your knees and cutting off blood circulation or becoming uncomfortable over time.
4. Measurement and identification of armrests
In the same way, draw an inch on a block of grid on a 32 1×6 piece of wood. The idea is to cut out the back two thirds of the armrests to leave more space for the body in between, while the widest part is the part where the arms rest on.
Again: You don’t have to do that. Predominantly decorative. You can create your own design or follow the simple drawings you see in the images on this page. The purpose of the grid is to make recommendations when designing your project so that it is smooth and reasonable.
5. Demarcation of the rail for the lower backrest
The wood used is only 3.5 wide. For example, if you draw an inch on a block of gauze on a 21.5 1×4 piece of wood, make sure you don’t design your pattern in such a way that there isn’t enough wood left to carry your weight on the thinnest part.
You don’t have to cut scallops out of these pieces. This is only the case if you prefer your back to bend inwards to fit the shape of your back. Many people prefer a flat back. The choice is yours. If you choose the flat option, do not overwrite the top rail of the backrest in the next step.
6. Demonstration upper rear rail
Repeat the above method to build one inch per grid block, but this time use 22 1×4 panels. If we’re talking about these lengths, they have to be cut. They are not delivered this way by the pallet.
Do not copy the same design on the upper rail. That’s possible, but I recommend that one of them is slightly wider on the circumference of the circle you’re drawing. But don’t go any further, for the same reasons as above.
7. Demarcation of the armrest
Cut out two 7.75 x 2.5 planks to be used as support for the armrests. They support the outside of the armrests where your arms will be. It’s just an extra structure to distribute the weight.
For decorative purposes, you can make a bend in the outer bottom and remove sharp corners which you can scrape off later with your foot.
8. It’s time to turn them all off
Attach the strings correctly before using any type of saw. Whatever you drew with your schedules, it’s time to cut them. They are basically hollow or convex curves. Be very careful when using saw blades of any kind.
9. Measures and cuts the front perch, the front crossbar and the front feet
You now need four 20 x 3.5 boards. There is one for the front perch, one for the front bow and two for the legs themselves. These are simple cuts without unnecessary design.
Put them aside and label them with what works best for you. That way they don’t get lost in the melee and you end up with a tape measure to look for them.
10. Marking and breaking of the rear jumper
For the lintel at the back, cut a piece of wood 18.5 x 3.5. This is the part that will support the back of the seat between the two legs/back.
11. Cut out rear supports
To make two backrests for your Adirondack chair on a pallet, measure 26 and the other side 23, using a 1×4 piece of wood. If desired, draw a straight line between these two brands. This allows the upper backrest to be tilted at a later stage. I would, it wouldn’t take long.
You don’t have to cut this piece diagonally, but it does remove corners you could scratch your hand on later and it has a more decorative look. It’s up to you to decide how you want to deal with it.
We need 9 1.75 for the seat battens. Just use a 3.5 wide board and separate it from the middle to get 1.75. Keep the length at 20. Another way of putting it is to cut five boards from 3.5 inches to 20 inches and then cut them perfectly in half.
All that remains is to observe the pilot holes at the ends of these pieces and mill them so as not to destroy the wood. If you do not use the test holes and strawberries, you run the risk of splitting the wood due to excessive wood movement. I’ll find time for that part, even if it seems unlikely.
Use these holes to attach the saddle strips to the two saddle rails prepared in step 3. Of course, we’re not ready for that yet. We’re getting ready.
13. marking and cutout for rear battens.
You need seven photo tracks, and you can use any of your imperfect parts. Their length must be between 34 and 36 years. The choice is yours. You can cut them into a cone shape or leave them vertically straight.
If you want to reduce it, measure a piece of 2.75 wide at the top and 2 wide at the bottom (don’t forget the vertical alignment) and saw it with a saw. If you don’t worry about tapering, you can make them all less than three inches wide.
When cutting the cones, cut only one side. Do not cut on both sides so that they are symmetrical. You don’t want them to be symmetrical. That’s a warning! Moreover, do not restrict the central panel at all.
14. Measuring and cutting the fan shaft
This step is also optional. If you don’t mind, or if you prefer a flat surface on top of your back, you can leave it in place. If you want to make a bend for purely decorative purposes, proceed as described below.
Place the pieces you cut out at the top in front of the back profile. Use a board along the undersides to align them perfectly. Be sure to align large pieces in the middle and small pieces along the edge of the back if you have differences in the size of the panel.
If you want to stretch these planks, put the thin pieces at the bottom so that the backside becomes wider towards the top. You may have to manipulate the plates until the design fits, but that will happen.
Now mark the bow in the middle with a pencil on both sides and try to make them symmetrical. Measure carefully and make both arches in the same way. You draw a very large circle, so you can use the piece of string at the bottom of the board to turn the pen in a smooth movement.
After measuring and drawing the arches, label each board with numbers from left to right so you know which board goes where when you assemble it. You can now cut the back plate of the fan plate by plate. After assembly, you can sand them to make them perfectly smooth.
15. Attaching the seat cheeks to the front legs and rear supports
We start the assembly by connecting the seating planks to the front legs and the rear supports. Lay these boards flat and rotate the seat so that the bottom is about 8.5 inches above the bottom of the front leg. From this point you have about 5 centimeters behind the front leg.
The downward sloping cheek of the seat extends to the underside of the backrest. If you want a wider angle with the back, you can cut a flat piece out of the lower back angle of the backrest so that it can also rest on the floor next to the underside of the backrest.
The distance between the back of the back and the front leg, upper and lower leg, must be 21 points to be safe. Take the measurements carefully so that everything is in order. Use a pencil or chalk. Do it for both sides of the Adirondack Paddle Chair.
Notice you’re going to change sides. So the seat support must be outside the rear support, but inside the front legs. This means that the back of the chair is about 2 times wider than the front. It is only a decorative element and is not essential.
16. Adhesives and screws for the front legs and seats
Now, to repair the front legs, we will use guide holes and counter holes. Once you have drilled two holes in the top plate and only half in the bottom plate, you are ready to insert the screws.
First apply wood glue between the two front legs and the seat support. You can then connect the two parts with a one centimetre long screw. If your screws are too long, you can cut off the protruding parts and then apply wood glue to fill the hole and cover the rest of the screw.
17. Do the same for the rows of seats and the rear support
We drill pilot holes to mount the rear support and use burs again. Use a washer, carriage bolt and nut instead of bolts to increase strength. It’s very simple because the front legs are already fixed and the seat support is placed on the underside of the rear support where the floor will be.
Drill the guide holes all the way through and apply adhesive before inserting the carriage bolt and tightening the nut. Tighten the screws so that the glue is properly accelerated. If someone pushes it, you can wipe it with a damp cloth.
18. Mount your two rear/seat/foot combinations and the rear jumper
Now that you have mounted the front foot, the front seat support and the rear support on both sides of the Adirondack do-it-yourself pallet truck, you need to align them lengthways and widthways. There is nothing else to do but align them so that the back is at the back and the front is at the front.
Make sure the seat crossbars are on the outside of the rear brackets and on the inside of the front legs if you have chosen this decorative part. So the seating area is slightly wider than the leg area of the seat.
They must be like mirror images of each other. Now, find the rear jumper so we can connect the two sides.
19. Fix the rear camber between the two sides.
To connect the rear jumper to the rear bracket, now measure one centimeter from the bottom of the rear bracket. The lower part refers to the part that touches the ground. This thumb should leave you another thumb on top. This keeps the hook in place to maintain its integrity.
Drill a few pilot holes and countersinks and then use glue between the side of the rear crossbar and the flat part of the rear support. Tie them up, one side at a time. This ensures that you have a flat chair.
20. Front jumper plug
To connect the front jumper, measure and mark under the cheek of the seat. The front arch rests on the underside of the seat cheek, just like in the middle of the two front legs.
It does not have to be perfectly centered, but make sure it is the same distance from the Default Front on both feet. This gives him stability and makes him visually more attractive.
Don’t forget that the saddle spar protrudes about five centimetres beyond the front leg, measured at the bottom of the saddle spar. Under the seat support, the front crossbar is pressed to support the weight of the seat. The front camber should be about 1.5 times weaker than that of the intermediate front legs.
21. Mounting the lower backrest rail
At this point, connect the lower rail of the rear panel. Mount this rail on the seat support towards the front, from where the seat support is connected to the back support. The distance to be covered depends on the slope of the backrest of the Adirondack Paddle Chair at the end of the day.
You can feel it by holding the backrest bar and visually measuring the tilt angle. I recommend at least 6 inches, maybe 8 inches, but not too far forward to fit into the bulges you may have cut into the seatbrackets.
Now attach it with screws to the two saddle arms after applying a strip of wood glue between them. Your chair should be strong enough to stand and handle without you having to worry about it moving.
22. Mounting the upper backrest rail
Now take the upper rail of the backrest and place it on the two backrest supports. The upper rail of the backrest should protrude on both sides when you try to centre it. You should be able to measure 2.5 on each side of the center, leaving 18.5 in between.
If your readings are wrong, that’s fine. Spread the difference and make sure it is centered. If you cut a diagonal at the top of the backrests, this beam is tilted backwards, but corresponds to the angle of the lower backrest support.
After drilling the holes in the marked area, place them on the backrest support and secure with glue and screws. Always glue and screw, otherwise you’ll hear squeaking noises.
23. Adhesives and screw holders for armrests
In this section, attach the armrests to the top of the front legs. Make two holes on the middle line of the front leg of the chair, from the top, using a drill. Now attach the brackets with screws and glue. Simple enough!
Remember that the upper edge of the front leg must match the edge of the brackets. They must form a smooth, flat T-shaped surface at the top so that the armrests can rest flat all around.
24. Fix the upper rail of the seat between the seat cheeks
Now use screws and glue to attach the 20 seat plate previously cut on the front of the seat. It is joined at the front of both cheeks from the seat to the edges without overlapping.
Don’t forget to use glue and screws first, with test holes and countersinks. The strawberries are most important here to prevent you from scratching your feet or getting your clothes stuck in the heads of the screws. We only take off from the front seat for more stability.
25. Rear centre bar connection
At this point, you’re gonna tie the center back. This creates a real surface on which you can lean with your back. To do this, drill a hole in the middle of the slats of the lower and upper backrest at the level of the slats of the middle backrest (the one from which you cut off the fan tail) to the guide of the lower backrest.
Drill a similar pilot hole in the upper rail of the backrest. You can look at the pilot hole in the middle of these rear blades. Use glue for screwing and lay the thin part if you choose conical boards, although this middle board is not conical.
26. Go to the outer edges
We’re starting to put the fantail together now. At this point, attach the rest of the backrest of the Adirondack chair to the pallet. Some suggest starting with the rear rails on the outer edge, but this requires disaster.
The middle sign should have been labeled number 4. Attach points 3 and 5 by placing the loose edges next to the center panel. You can leave a space of about 1/4 to 1/2 inch between them. This ensures air circulation and keeps your back cool when you sit down in your future chair.
After confirming the numbers 3 and 5 in the same way as the center panel, confirm the numbers 2 and 6, and finally the numbers 1 and 7. If you do it right, the tenons create a natural torch at the back so that the top is wider than the bottom. When mounting, always keep the free and flat side facing the centre plate.
27. Landing plate connections
Before screwing anything in this step, you should make a test drive, placing each board in its potential place on the seat beam. This will give you an idea of the space you need. These spaces provide air circulation, just like the back.
Now place the nine cut-out plank chairs and attach them to the seat supports by pre-drilling and milling the bolt heads. Again, this is important so you don’t scratch your buttocks, feet or clothes. Don’t forget the glue.
Assemble the nine seat planks by bending them evenly at the front of the seat rails, at the back at the protrusions (if you want to cut them out) and lower at the backrest. That’s all there is.
Hold the armrests in place and use a drill to drill three holes in the triangular knot of the armrest supports and the front legs. Here is the flat T-shape at the top of the front legs. Glue and screw them.
Measure up to 20 on the rear floor stands. If possible, try to place the armrests at this height and stick the area between the armrests and the backrests. Then make a test hole and countersink it and screw it in.
29. Use wood glue or putty to fill holes.
Finally, you can use wood filler to fill any holes. Once it is dry, I come back and sand the whole chair on every surface to remove splinters and blemishes.
30. Stain and Seal or Paint your Adirondac Box Chair
Your Adirondack Paddle Chair is now assembled and polished! Congratulations! Now all we have to do is seal the tree. Don’t worry too much, because the pallets are impregnated under pressure and can remain outside, but they still need to be sealed.
You can then choose to paint the tree, leave it as it is or paint it in the colour of your choice. I would use latex paint because it’s much more water-resistant. However, it may form blisters over time, in which case you can sand it down and repaint it.
Either way, you’re ready and have a spotless chair to put on your porch, terrace or lawn. You can be creative and make cup holders, an umbrella or anything else you can imagine. Have fun!
Here are our plans for the Adirondackseries.
You’re finally done with your adirondack paddle chair. We generally recommend sanding the chair, otherwise scratches and chips may appear. It is in any case possible to lightly polish the chair. After the final steps, the chair is ready for use.
Enjoy the project. The result is a very comfortable chair on which you and your family can sit with pleasure. This Adirondack wooden paddle chair is a great addition and will also be a great way to start a conversation.
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Editor: Rick Sausage
Rick is a home design consultant and enthusiast whose life revolves around everything that has to do with home and garden. What started as a hobby has become a true mine of information and inspiration for both professionals and owners. Rick owns and publishes many of our content providers. To find out more about Rick and the operation, click here.
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