HOW TO
MAKE A
CHAIR
OPEN
SOURCE
DESIGN AND INSTRUCTIONS BY JAMES TOOZE
TOOLS NEEDED
5m
Hand saw
Tape measure
Carpenters square
HB
4mm drill bit
Protractor
Pencil
PZ #2 screw
-driver bit *
2 x hand clamps
Sand paper
Block plane
Drill / driver
Countersink
*PZ #2 or (pozi 2) is a screw head size.
MATERIALS NEEDED
All plywood is 18mm thick
Plywood for the jig
all dimensions in mm
Plywood for each chair
all dimensions in mm
quantity
2
2
2
2
2
2
2
2
1
1
width
55
55
55
55
55
55
180
100
180
420
quantity
length
x
x
x
x
x
x
x
x
x
x
1
1
1
1
450
420
400
380
350
310
200
150
380
380
Softwood (pine) for each chair
all dimensions in mm
quantity
thickness
6
30
width
x
30
width
55
55
55
650
length
x
x
x
x
650
350
200
380
Screws for the jig
all PZ #2 head
2 of 4mm x 30mm
Screws for the chair
all PZ #2 head
71 of 4mm x 30mm
6 of 4mm x 45mm
4 of 4mm x 45mm
12 of 4mm x 75mm
length
x
380
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.
02
STEP 1 - MAKING THE JIG
* a jig is a tool that allows the for the repeating of a process more accuratly. This part is vital if you do
not have access to power tools as it will help you to measure and cut all of the components for the
sides.
part
quantity
1
2
3
4
1
1
1
1
width
55 mm
55 mm
55 mm
650 mm
length
x
x
x
x
650 mm
350 mm
200 mm
380 mm
2 of 4mm x 30mm
6 of 4mm x 45mm
1) position part 1 onto part 4 as per drawing 1 and fix in place using 4 x 30mm screws.
2) measure in roughly 5mm from each edge and mark a line at 90° on the left and at 100° on the right
3) screw on parts 2 and 3 using 4 x 45mm screws making sure they are accurately lined up, the edge
of part 2 with the 100° line (right) and part 3 with the 90° (left). When attaching these pieces first put
one screw in then adjust to correct angle then when confident they are at the desired angle fix in
place with the second screw.
4) with parts 2 and 3 screwed in place use them as a guide to cut off the ends sticking out from part
1, accuracy is important here, try to cut as tight to the guide as possible and as straight / vertical as
you can.
PART 3
5) Refer to drawing 3 for the measurements you need for the chair to mark out onto the jig.
90
PART 4
PART 2
200 mm
PART 1
100
JIG DRAWING 1
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03
0
20
mm
JIG DRAWING 3
450
420
350
380
400
380
420
450
310
JIG DRAWING 2
measurement from end
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.
04
STEP 2 - USING THE JIG - CUTTING THE PARTS
part
A
B
C
D
E
F
G
H
quantity
width
2
2
2
2
2
2
2
2
length
55 mm
55 mm
55 mm
55 mm
55 mm
55 mm
180 mm
100 mm
x
x
x
x
x
x
x
x
450 mm
420 mm
400 mm
380 mm
350 mm
310 mm
200 mm
150 mm
1) To cut the parts position them tight into the jig as per drawing 4 up to the measurements for each
part. Again try to be as accurate as possible, tight to the guide and vertical. If you are cutting from long
lengths, once you have cut an angled cut (100°) the jig can be rotated to cut the next piece to length
with a square cut (90°). Cut the longest lengths first and those with cuts at 100° at one end. As you cut
the parts label them with a pencil for easy identification.
* remove dust build-up
underneath the saw
guide to prevent
inaccurate positioning
of the piece to be cut!
450
420
400
380
350
310
380
420
450
2) Once you have cut parts A to F make sure that the 2 versions of each are accurate and the same. Then
put them to one side.
PART A
*
100 angle
on one end
JIG DRAWING 4
rest saw against
guide to cut.
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05
200 mm
180 mm
PART G
PART G
12 mm
12 mm
JIG DRAWING 5
3) Take parts G and mark out as per drawing 5, put part into jig,
positioning the marked in line with the guide rail, cut off the bit
sticking out and turn over and repeat.
12 mm
4) Mark out with pencil on to parts G as per drawing 6.
5) Separate parts A – H into two piles with one
piece of each part, making left and right hand
piles. Using the pencil mark onto each piece
whether it is left or right. It is important to make
sure when connecting parts you make a lefthand
side of the chair and a righthand side and not two
of the same!!
100 mm
100 mm
JIG DRAWING 6
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06
STEP 3 - MAKING THE CHAIR - SIDES
PA
R
56 of 4mm x 30mm
*
TB
line up the top
right corner of part
B with the centre mark
on part G making
sure that it is posi- 100 mm
tioned along the
centre line.
100 mm
R
PA
RT
PA
TG
T
PAR
R
PA
TH
A
D
* TIP – to mark out the screw holes
quickly, first measure your desired distance in,
in this case 10mm. Hold the pencil tightly and
using the fingers underneath the pencil run them
along the edge of your work piece to get a fairly
consistent line. When repeating on other pieces
refer back to you original mark. Drill a hole for the
screws and then countersink, do this before
putting it in place.
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07
R
PA
TC
* Check that this
is a right angle.
R
PA
* Repeat up to this stage
but for the lefthand side. Put
the two sides together to check
that both sides are the same. If you
need to adjust do so by marking which part
you want to adjust and by how much. The
parts can be adjusted by loosening the screws
in that piece and then tightening back up in
the desired position.
TF
R
PA
TE
m
0m
45
m
m
5
43
Mark the
measurements onto
the sides and using the
long edge of the jig line up
the two marks and clamp in
place. Use the edge of the jig
as a guide to cut straight so
that the bottom of the chair
legs are flat to the floor.
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08
Once the sides
are screwed together
use the saw to cut off the
excess material from bracket parts
G + H. Try to cut as straight and
carefully as possible
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09
34mm
Taking both sides mark out as below the positions
for the screw hole to assemble the chair. Drill and
contersink the holes making sure to countersink
the correct face.
16mm
364mm
404mm
210mm
16mm
34mm
for these two
position 9mm from
top edge and
20mm in from
corner brackets
230mm
27.5mm
* in the middle
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10
STEP 4 - MAKING THE CHAIR - SEAT + BACK
part
I
J
quantity
1
1
width
length
180mm
420 mm
x
x
380 mm
380 mm
15 of 4mm x 30mm
Softwood (pine) for each chair
all dimensions in mm
part
K
quantity
6
thickness
32mm
width
x
32mm
length
x
380 mm
*The sixth bit is for the back leg support in STEP 5
Pre drill and countersink parts holes before
assembly. To line up the mid batot in the centre of
the seat mark as indicated below. It is essential that
the battons are screwed on in line with the
plywood parts, use the clamps to hold pieces
ensure correct alignment prior to screwing.
190mm
60mm
16mm
Before assembling the
chair in step 4, plane / sand
the edges of the back and
seat, removing the edge to
approximately a 5mm
radius to make for a more
comfortable chair.
210mm
mark the centre of part J on
both sides and the centre of
the end of the batton on
both ends to line up.
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11
STEP 5 - MAKING THE CHAIR - ASSEMBLY
4 of 4mm x 45mm
12 of 4mm x 75mm
To screw together start by attaching the back to
one side then attach the seat. Next screw on the
otherside and finally attach the back rail making
sure that you position it centrally to the screw hole
in the rear leg.
Again it is important to align the parts prior to
screwing together - start with one screw and if
correctly placed, do the rest, if not loosen it a bit
and reposition then put in one of the other screws
to hold it. Then fix all screws.
Using the sandpaper / block plane put a radius on the corners that meet the seat and back. Sand all
edges of the chair to remove sharp edges and risk of splinters. Sand edges to smooth.
DONE - you can now keep the chair as it is or apply a water based (acrylic) varnish or paint it, or paint
some of it.
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12
STEP 6 - CHANGE WHATEVER YOU WANT
I hope this has been useful. Please use it as a guide. Feel free to alter / adapt and reinterpret.
PROJECT DISCLAIMER
Your safety is your own responsibility, including proper use of equipment and safety gear, and determining
whether you have adequate skill and experience. Powertools, electricity and other resourcesused for these
projects are highly dangerous, unless used properly and withadequate precautions, including correct
safety equipment and proper environments. Use of the instructions and suggestions in the How to make a
chair open source (Open chair) is at your own risk. The designer disclaims all responsibility for any resulting
damage, injury, or expense in the making of the project, or usage of the finished articles thereafter. It is
your responsibility to make sure that your activities comply with applicable laws, including copyright.
Anyone, except for industry and dealers (in their professional capacities), can use these designs for personal
use. I ask those who construct these designs, and variations in particular, to send photographs via their
personal websites, which can be accessed via www.jamestooze.wordpress.com
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13