DIY Modern Plywood Chair | How To Make Two Chairs From One Sheet | #rocklerplywoodchallenge

DIY Modern Plywood Chair | How To Make Two Chairs From One Sheet | #rocklerplywoodchallenge


hey welcome back to Jonny builds where
this week I built two of these simple modern plywood chairs out of one sheet
of plywood and I did it all for the modern maker podcast Rockler plywood
challenge let’s see how I did it this project starts with a single sheet
of 4 foot by 8 foot 3/4 inch Baltic birch plywood each one of these chairs
is made from a half sheet of plywood so I started by marking out and breaking
down the sheet of plywood in half with my track saw next I set my table saw
fence to 5 inches and ripped 4 of these 5 inch wide strips and these will serve
as the back legs and uprights of the chair and since I’m making 2 chairs I
rip 4 of these strips from each one of the half sheets of plywood here you see
me using two scraps of plywood to set the fence on the table saw and ripping
down the rest of each one of the half sheets since the plywood is actually a
little bit less than 3/4 inches this is an important step for measuring and
marking for the entire rest of the project you’ll see what I mean as we go
along and when it’s all done you’ll end up with 34 of these one and a half inch
strips and moving on to the back leg uprights I measured them at 32 inches
set up a stop block and then cut them over on the miter saw the offcuts from the back legs get
ripped down in half and become the seatback horizontal stretchers all of
the one and a half inch strips get cut down to 17 inches and for each chair you
need 33 of these pieces then I could organize and lay out all the pieces that
I would need for each chair starting with 21 of these strips that get
laminated together to make up the seat bottom next I glued up all the strips
for the seat and I really try to keep these as flat as possible to save time
for sanding later next I glued up six pairs of these
one-and-a-half inch pieces for each chair to become the lower stretchers and
front legs I also glued up pairs of the five-inch wide pieces that become the
back legs you need 2 for each chair I made a template on some half inch MDF
and to mark out the angles I just use this cheap protractor the back legs
splay inward at 6 degrees I marked out a 26 inch line at this 6 degree angle and
then use one of the laminated pairs of one and a half inch strips
to set the thickness the backrest gets marked out at 6 inches long and it’s
plays backwards at 7 degrees I use my bandsaw to cut out the leg
template then I transfer the template on to each one of the four leg blanks I cut
out the legs in the bandsaw making sure to cut outside of the lines that I had
marked I attach the template to the legs I cut out with some double-sided tape
and protip don’t use this much tape this was really hard to get off this is a one
and a half inch flush trim bit and that top bearing rides against the template
and trims the leg blank to match the template exactly then I hit all the legs
with some 120 grit sandpaper to clean any marks left by the router bed after
squaring up the front of the seat I set the saw blade to 6 degrees and this will
allow the back of the seat to ramesh the 6 degree angle of the legs each one of
the seats gets cut to 16 inches and this is measured from where the seat is at
its longest this is a good time to sand the seats up to 120 grit and it’s also a
good time for you to hit that subscribe button to stay up to date with all the
products I’ve got coming up I measured 15 and a half inches up on the back legs
which marks out where the bottom of the seat will go the lower stretchers sit an
inch and a half and below the seat and I marked out their locations as well
because of the angle I couldn’t use dominoes to attach the backs of the
seats and the stretchers so I’ve made this drilling template with
three-eighths inch holes to drive in screws later
I drilled a few pilot holes and attach the back legs to the seats with two and
a half inch screws to make the front legs I use one of the
laminated 17 inch long pieces and then cut it down to 15 inches on the crosscut
sled the front legs get attached to the seat with Domino’s and here you see me
marking out alignment lines for that again you don’t need a domino to build
these chairs you could use screws plug in with dowels like I did on the back of
the seats it’s just what I have and what works easiest for me I set my saw blade
to 7 degrees and then cut bevels in the upper stretchers to match the angle of
the backrest all the horizontal stretchers except for the side
stretchers get cut down to 12 inches wide I marked out the locations for the
Domino’s on the upper stretchers and then transfer these marks over to the
backrest where they will attach I measured five and a half inches up
from the bottom of the legs and cut in Domino’s for the lower stretchers I then
did a dry assembly of the chair using all the stretchers that I had cut so far
there we go now on the side stretchers there’s a six
degree angle in the back and then it butts up to that 90 degree angle on the
front so you have to measure these out and cut them to fit I made small passes
on the table saw in order to get that perfect fit which ended up being 14 and
7/8 inch at its longest point here I’m laying out the location of that French
stretcher which again is an inch and a half below the bottom of the seat I
drilled in a few pilot holes for the side stretchers and then attached them
the screws but then I had to unattach everything take it all apart to sand
everything up and get it ready for final assembly I started putting this chair together by
attaching the front stretcher to the legs and then I could attach the two
side stretchers as well the rest of the assembly is just like you saw me do in
the dry fit only this time I’m adding glue and for the last bit of assembly I’m
using these 3/8 inch oak dowels to plug up all the screw holes and finally I can move on to finishing
I used a clear matte polycrylic applied three coats and these chairs were all
finished hey everybody thanks for watching and thanks to the guys over at
the modern maker podcast mic Ben and Chris for putting on this one sheet of
plywood challenge now a couple months ago I drew up the design for this very
simple yet modern plywood chair and I was listening to the modern maker
podcast and they were talking about the upcoming challenge and I got the feeling
that it was gonna be a 1 sheet of plywood challenge so I held off and man
I’m really glad that I did so this is now my official entry into the Rockler
plywood challenge and I’m really happy with the way it turned out I I really
like working with Baltic birch it’s one of my favorite materials if you haven’t
watched it already go check out my apply wood dining table there’s a link to it
up in the corner and I did the same technique I laminated multiple layers of
Baltic birch plywood together and one thing about Baltic birch is it’s just a
really nice material to work with when you laminate it together and you see all
the different plies it looks really good and gives the piece a very unique sleep
linear look and I just love the way it looks I really wanted to show off all
the plies in the seat I tried to limit the veneer face as much as possible but
I think it looks cool the contrast of having the plies on the front with the
veneer face on the side so let me know what you think about this building in
the comments down below if you liked it make sure you hit that thumbs up and if
you haven’t already please subscribe but really helps my channel grow and a big
thank you to everyone that’s subscribed all ready you can check out behind the
scenes stuff on Instagram at Johnny builds so thank you everybody for
checking this one out and we’ll see you back here next time you

100 Replies to “DIY Modern Plywood Chair | How To Make Two Chairs From One Sheet | #rocklerplywoodchallenge”

  1. The lamination effect looks beautiful, glad you showed it off at the end. It looked like the full sheet might have had some bow in it. Does the glueing take care of that or is it not really worth worrying t?

  2. Ma new favorite maker! Nice job Jonny!
    I tagged you last saturday on instagram whit my new fruit bowl, your channel is a very large pot of inspiration for me!

  3. Sir, you are not a carpenter, you are a designer, a very good one. I like your videos and your designs. Keep building art. Love from Spain ♡

  4. Fantastic use of that whole sheet! On some things, I don’t like seeing all of the plys like this. However, it looks great on these chairs! Great video and project, Jonny!

  5. Looks awesome! You and I have a very similar approach to our plywood challenge builds….templates, dowels, modern style…are you my plywood brother from another mother?? 😂. I started editing my video yesterday. Hopefully be done in a few days 👍🏻

  6. Very nice project! I've been thinking of doing the plywood challenge too, so many options, not sure which to pick!

  7. I definitely have to get my editing up to par for this challenge. I have a few really cool ideas so far. Trying to sway towards the modern side since I know that's where the guys taste is when judging it

  8. This is a great build! I've been thinking of how to build good looking plywood chairs. This is a serious contender. Also, I really like the explanation! I appreciate knowing what you're doing, helps keep the video interesting to me.

  9. Great entry to the challenge. I like how such a simple material like plywood can be turned into something so refined with the right touch. Well done!!

  10. Jonny,, I found you on your plywood challenge build. good job. I tried to find your video intro and you don’t have one. I subbed anyway. look forward to more good quality work

  11. Nice build Jonny, what the thickness size of your blade is on your bandsaw? And personally I would of used dowels and or loose tennons to do all of the joinery

  12. You missed good opportunities to lap joint in the legs. Would have added a ton of strength and got rid of all these screws and dominos.

    Looks good though!

  13. Looks good man. Maybe add a tiny chamfer(45) to relieve the edges but keep them crisp looking. Where I live Baltic Birch plywood is sold in 5'x5' sheets (1524mm x 1524mm). Kind of hard to load. Maybe I need a Baltic pickup with a short wide bed.

  14. Awesome project, Jonny! The chairs look amazing. I was surprised you went with laminating the seat instead of a sheet, but it’s awesome!

  15. Super cool design. Another way for the front and back stretchers would possibly be to do the same method that you did for the seat and then cut them to length. This way all the lines run the same way from the different layers. More work but potentially worth it?

  16. You could have used dominos for the angled pieces too. You drill a deep Domino hole first, then you cut the angle.

  17. the awesome channel just only one thing I have found wrong your strings from the jacket you were put them in the side of the jacket had a friend had died after he jacket strings got to catch and pulled him in the saw happened so fast no one ready know what happen that day
    his family never reopen the cabinet shop be couse of his drath

  18. You have made two very nice chairs from one sheet of plywood, very well designed and assembled,I have just one e small moan!,the chairs have all 90% sharp corners ,I personally think you should have rounded over the seat edges,to lessen the chance of the seat edges break8ng off,but your project gets my thumbs up

  19. Very nice use of plywood and a neat design but I suspect these chairs will fail at the point where the seat meets the back legs – four screws just do not have the shear strength to support what might be a 200Lb man. I would have used two vertically cut dominoes on each leg at that point, or even better dado the seat slightly into the back legs – then the screws would work because they would not be load-bearing.

  20. Та ещё раскрывашка. Однако можно позавидовать качеству фанеры.

  21. I am building these and have a question, you said you measured 15 1/2 on back legs for seat, but then you said 15" for the height of the front leg, is the seat tipped forward a bit?

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