DIY Modern Curved Plywood Lounger Chair

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

Easel **FREE ACCOUNT**: https://goo.gl/MpCrzT

X-Carve Machine: https://goo.gl/4cA9JS (affiliate link)

The Tools Used: (affiliate links)

• Saw Stop Table Saw: http://amzn.to/2zC32kU

• Jig Saw: http://amzn.to/2zC32kU

• Sander: http://amzn.to/2zC32kU

• X-Carve Machine: http://amzn.to/2zC32kU

-------Products Used-------

• Half a sheet of 3/4" Birch plywood

• Waterlox Finish: https://goo.gl/JE5VHB

------Patreon Page THANKS!------ Help support the show and get extra content! Thank you Shane VanBuskirk for supporting our channel:) https://goo.gl/jwVVcQ

Cut Your Plywood to Size

Screen Shot 2017-10-20 at 11.12.36 AM.png

You will need a 30" x 24" piece of 3/4" plywood.

CNC the Live Hinge.

Screen Shot 2017-10-20 at 11.12.53 AM.png

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

Easel **FREE ACCOUNT**: https://goo.gl/MpCrzT
X-Carve Machine: https://goo.gl/4cA9JS

Cut the Tongue & Groove Joint

Screen Shot 2017-10-20 at 11.13.15 AM.png

Screen Shot 2017-10-20 at 11.13.29 AM.png

Screen Shot 2017-10-20 at 11.13.42 AM.png

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.

Cutting Slots for Straps

Screen Shot 2017-10-20 at 11.14.08 AM.png

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.

Making the Legs

Screen Shot 2017-10-20 at 11.13.52 AM.png

Screen Shot 2017-10-20 at 11.14.17 AM.png

Screen Shot 2017-10-20 at 11.14.29 AM.png

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. Lastly attach the legs to the chair with glue and screws. We plugged the holes to give a seamless look.

Add the Finish

Screen Shot 2017-10-20 at 11.17.33 AM.png

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

Add Your Straps

Screen Shot 2017-10-20 at 11.17.51 AM.png

Screen Shot 2017-10-20 at 11.17.58 AM.png

Screen Shot 2017-10-20 at 11.18.08 AM.png

We used 1" wide webbing straps for holding the chair up. We used rivets to attach the straps and an adjustable connector to allow you to adjust the back position.