Build a Comfortable Outdoor Chair: Bent Lamination

Synopsis: Part 1 of this garden chair project involves making the bent laminations that are used for the sweeping curves in the arms, seat, and back slats. The process of clamping a stack of thin plies onto a curved form to make these laminations is a crucial part of the project, and is covered in depth here. Michael Fortune shares the secrets of success he’s learned over 40 years of making furniture. Two bending forms are all that’s needed for all the curved parts in the project, and you’ll learn to make and use them here.

Read “The Garden Chair, Part 2: Assembly,” (FWW #241).

I own several classic but tired Adirondack chairs. While they are comfortable enough for reading or relaxing, they can be difficult to get in and out of. So a few years ago, I decided to redesign the classic with better ergonomics. But I didn’t stop there. The graceful arc of day-lily leaves and the bloom-laden stalks in my garden inspired me to add organic curves and really make this garden chair my own.

The first version of this chair was simple (see “Three Outdoor Chairs,” FWW #212). I designed that one with the swooping curved arms you see here, but I made the seat and back slats flat to bring the chair to a lower price point. On this version, I curved the slats for comfort. It’s the same way I would do it for myself.

What makes those long curves possible, particularly in the broad arms, is bent lamination-basically, clamping a stack of thin plies onto a curved form for glue-up. That’s where the chair project begins. I’ll cover the process in depth here, giving you all the secrets to success that I’ve learned over 40 years of making curved furniture. Bent lamination is surprisingly straightforward once you understand the basic steps. Learn them and you’ll take your furniture designs to a new level.

I chose to make this chair in mahogany, but white oak, hemlock, and cedar are also good choices. All stand up to the weather well, and all bend nicely.

Download the plans for this chair from the Digital Plans Library. Plus, browse 100+ other plans available for members only.

For the full article, download the PDF below.

Fine Woodworking Recommended Products

Ridgid EB4424 Oscillating Spindle/Belt Sander

With five spindles sized from 1/2 in. to 2 in. and a 4 X 24-in. belt, this sander has become a staple in many a shop Fine Woodworking visits.

Buy at Amazon