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A deep, cushion-ready outdoor lounge chair cut entirely from six 2x4s in three lengths — and a lesson in driving screws at angles instead of buying a jig.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Legs, arms, and frame pieces | 10 | 1 1/2" × 3 1/2" × 25 1/2" | — | ☐ |
| Arm rests | 2 | 1 1/2" × 3 1/2" × 28 1/2" | — | ☐ |
| Seat and back slats Or the width of your cushions. Cut at 23-3/4" to get four per 10-foot board. | 10 | 1 1/2" × 3 1/2" × 24" | — | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| 2x4, 10 ft 10-footers cut cleanly into four 23-3/4" slats — the plan's own efficiency tip. | 6 each | ☐ |
| Construction screws, #9 x 2-3/4", star drive, exterior | 75 each | ☐ |
| Exterior stain or paint Pre-finish the boards before assembly. Partial quart per chair. | 1 quart | ☐ |
| Outdoor deep-seat cushion set Buy or measure FIRST — the slat length is cut to the cushion width. Not in the cost estimate. | 1 each | ☐ |
Overall cost: $$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Tools: Drill / Driver, Speed Square. Materials: 2x4, 10 ft, Construction screws, #9 x 2-3/4", star drive, exterior
Attach an arm rest across two legs with the 2-3/4" screws, two per joint. Build two identical frames — clamp them together and compare before moving on.
Tools: Drill / Driver, Tape Measure. Materials: 2x4, 10 ft, Construction screws, #9 x 2-3/4", star drive, exterior
Screw the middle support between the legs of each arm frame per the diagram. This rail is what the seat frame lands on, so its height sets your seat height — check it against the cushion stack you're planning.
Tools: Drill / Driver. Materials: 2x4, 10 ft, Construction screws, #9 x 2-3/4", star drive, exterior
Add the second middle support directly underneath the first — two screws per end, plus two driven down from the top edge of the upper board into it. The doubled rail turns a shelf into a beam.
Tools: Drill / Driver, Speed Square, Tape Measure. Materials: 2x4, 10 ft, Construction screws, #9 x 2-3/4", star drive, exterior
Assemble the seat frame rectangle with 2-3/4" screws, two per end. Square it by matching diagonals.
Tools: Drill / Driver. Materials: Construction screws, #9 x 2-3/4", star drive, exterior
Fasten the seat frame between the two arm assemblies with four screws per side — spread as far apart as the joint allows, top/bottom and end to end, and drive them at slightly different angles. Wide spacing resists the pry; opposing angles resist the pull. This joint carries the sitter, so give it all four screws.
Tools: Drill / Driver, Pocket Hole Jig. Materials: 2x4, 10 ft, Construction screws, #9 x 2-3/4", star drive, exterior
Pocket holes shine here if you have the jig. If not, use the plan's hand technique: start each screw nearly perpendicular about 1" from the board end, and once the threads bite, tip the driver to 45° and finish into the meeting board. Two screws per end, lower support first so the drill still fits in the opening.
Tools: Drill / Driver, Random Orbit Sander. Materials: 2x4, 10 ft, Construction screws, #9 x 2-3/4", star drive, exterior, Outdoor deep-seat cushion set
Lay out the slats with even spacing and screw down, two screws per end. Sand, touch up the finish on cut ends, drop the cushions in, and go test the recline with something cold.