DIY Modern Curved Plywood Lounger Chair

Woodbrew
by Woodbrew
8 Materials
$40
6 Hours
Medium
This week, we decided to put our design and engineering skills to the test by building a wooden live hinge lounge chair. The chair is made from 3/4" plywood and has walnut end caps. We used a technique called live hinge, where you take out material in a uniform pattern, which allows the plywood to compress and then bend.


BUILD FILES Check out the build files for this chair! Send us a link via Instagram DM to your modified version. https://goo.gl/CKK3YM




 Cut Your Plywood to Size. You will need a 30" x 24" piece of 3/4" plywood.
We used the Inventables X-Carve to cut our live hinge. You could use a jig saw if you don't have access to a cnc.Here are the files we used: https://goo.gl/CKK3YM
We decided to attach Walnut on either end of our plywood for added interest. The walnut is 3/4" x 5" x 24". We cut a groove in the end of the plywood and a tongue in the walnut.
Use clamps and glue to join them together.
Cut the legs out using the build files below. You will need to make two pairs of 3/4" plywood legs. Glue two pieces together to form a thicker leg.
Attach the legs to the chair with glue and screws. We plugged the holes to give a seamless look.
At both ends of the chair you need to cut a slot that is 1/8" x 1" all the way through the walnut. You will use this slot to attach the straps later.
We used a product called Waterlox to finish our chair. This is a super durable tung oil and resin infused finish. Check it out here: https://goo.gl/JE5VHB
We used 1" wide webbing straps for holding the chair up. We used rivets to attach the straps.
Add adjustable connectors to allow you to adjust the back position.
DONE!
Suggested materials:
  • Waterlox Finish   (https://goo.gl/JE5VHB)
  • X-Carve Machine   (https://goo.gl/4cA9JS)
  • Easel   (https://goo.gl/MpCrzT)
See all materials
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