how to make a chair open source (06-11) - jamestooze · safety equipment and proper environments....

HOW TO MAKE A CHAIR OPEN SOURCE

DESIGN AND INSTRUCTIONS BY JAMES TOOZE

OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.02

MATERIALS NEEDED

HB

5 m

Carpenters square

Protractor

Tape measure Hand saw

PZ #2 screw-driver bit *

4mm drill bit

Countersink

2 x hand clamps

Block planeSand paper

Pencil

Drill / driver

2 55 x 4502 55 x 4202 55 x 4002 55 x 3802 55 x 3502 55 x 3102 180 x 2002 100 x 1501 180 x 3801 420 x 380

Plywood for each chairall dimensions in mm

quantity width length

6 30 x 30 x 380

Softwood (pine) for each chairall dimensions in mm

quantity thickness width length

1 55 x 6501 55 x 3501 55 x 2001 650 x 380

Plywood for the jigall dimensions in mm

quantity width length

TOOLS NEEDED

2 of 4mm x 30mm

6 of 4mm x 45mmScrews for the jig

all PZ #2 head

71 of 4mm x 30mm

4 of 4mm x 45mm

12 of 4mm x 75mm

Screws for the chairall PZ #2 head

*PZ #2 or (pozi 2) is a screw head size.

All plywood is 18mm thick

90

100

PART

3

PART 1

PART 4

PART 220

0 m

m

JIG DRAWING 1


STEP 1 - MAKING THE JIG

1 1 55 mm x 650 mm

2 1 55 mm x 350 mm

3 1 55 mm x 200 mm

4 1 650 mm x 380 mm

part quantity width length

* a jig is a tool that allows the for the repeating of a process more accuratly. This part is vital if you do not have access to power tools as it will help you to measure and cut all of the components for the sides.

1) position part 1 onto part 4 as per drawing 1 and �x in place using 4 x 30mm screws.

2) measure in roughly 5mm from each edge and mark a line at 90° on the left and at 100° on the right

3) screw on parts 2 and 3 using 4 x 45mm screws making sure they are accurately lined up, the edge of part 2 with the 100° line (right) and part 3 with the 90° (left). When attaching these pieces �rst put one screw in then adjust to correct angle then when con�dent they are at the desired angle �x in place with the second screw.

4) with parts 2 and 3 screwed in place use them as a guide to cut o� the ends sticking out from part 1, accuracy is important here, try to cut as tight to the guide as possible and as straight / vertical as you can.

5) Refer to drawing 3 for the measurements you need for the chair to mark out onto the jig.

2 of 4mm x 30mm

6 of 4mm x 45mm

200

mm

JIG DRAWING 1

450

420

380

350

400

310

450

420

380

200 mm

JIG DRAWING 2

JIG DRAWING 3 measurement from end


450

420

380

350

400

310

450

420

380

PART A

*100 angle on one end


STEP 2 - USING THE JIG - CUTTING THE PARTS

A 2 55 mm x 450 mm

B 2 55 mm x 420 mm

C 2 55 mm x 400 mm

D 2 55 mm x 380 mm

E 2 55 mm x 350 mm

F 2 55 mm x 310 mm

G 2 180 mm x 200 mm

H 2 100 mm x 150 mm


1) To cut the parts position them tight into the jig as per drawing 4 up to the measurements for each part. Again try to be as accurate as possible, tight to the guide and vertical. If you are cutting from long lengths, once you have cut an angled cut (100°) the jig can be rotated to cut the next piece to length with a square cut (90°). Cut the longest lengths �rst and those with cuts at 100° at one end. As you cut the parts label them with a pencil for easy identi�cation.

2) Once you have cut parts A to F make sure that the 2 versions of each are accurate and the same. Then put them to one side.

JIG DRAWING 4

* remove dust build-up underneath the saw guide to prevent inaccurate positioning of the piece to be cut!

rest saw against guide to cut.

12 mm

PART G


180 mm

200 mm

12 mm

PART G

12 mm3) Take parts G and mark out as per drawing 5, put part into jig, positioning the marked in line with the guide rail, cut o� the bit sticking out and turn over and repeat.

4) Mark out with pencil on to parts G as per drawing 6.

5) Separate parts A – H into two piles with one piece of each part, making left and right hand piles. Using the pencil mark onto each piece whether it is left or right. It is important to make sure when connecting parts you make a lefthand side of the chair and a righthand side and not two of the same!!

JIG DRAWING 5

JIG DRAWING 6

100 mm

100 mm


56 of 4mm x 30mm

100 mm

100 mm

PART B

PART G PART A

PART D

PART H

STEP 3 - MAKING THE CHAIR - SIDES

* TIP – to mark out the screw holes quickly, �rst measure your desired distance in,

in this case 10mm. Hold the pencil tightly and using the �ngers underneath the pencil run them along the edge of your work piece to get a fairly consistent line. When repeating on other pieces refer back to you original mark. Drill a hole for the screws and then countersink, do this before putting it in place.

*line up the top right corner of part B with the centre mark on part G making sure that it is posi-tioned along the centre line.


450mm

435mm

PART C

PART F

PART E

* Repeat up to this stage but for the lefthand side. Put

the two sides together to check that both sides are the same. If you

need to adjust do so by marking which part you want to adjust and by how much. The parts can be adjusted by loosening the screws in that piece and then tightening back up in the desired position.

* Check that this is a right angle.

Mark the measurements onto

the sides and using the long edge of the jig line up the two marks and clamp in place. Use the edge of the jig as a guide to cut straight so that the bottom of the chair legs are �at to the �oor.


Once the sides are screwed together

use the saw to cut o� the excess material from bracket parts

G + H. Try to cut as straight and carefully as possible


34mm

16mm

364mm

34mm

16mm

210mm

230mm

27.5mm * in the middle

404mm

for these two position 9mm from top edge and 20mm in from corner brackets

Taking both sides mark out as below the positions for the screw hole to assemble the chair. Drill and contersink the holes making sure to countersink the correct face.


STEP 4 - MAKING THE CHAIR - SEAT + BACK

I 1 180mm x 380 mm

J 1 420 mm x 380 mm


K 6 32mm x 32mm x 380 mm

part quantity thickness width length

15 of 4mm x 30mm

Softwood (pine) for each chairall dimensions in mm

60mm

190mm

16mm

210mm

Before assembling the chair in step 4, plane / sand the edges of the back and seat, removing the edge to approximately a 5mm radius to make for a more comfortable chair.

*The sixth bit is for the back leg support in STEP 5

Pre drill and countersink parts holes before assembly. To line up the mid batot in the centre of the seat mark as indicated below. It is essential that the battons are screwed on in line with the plywood parts, use the clamps to hold pieces ensure correct alignment prior to screwing.

mark the centre of part J on both sides and the centre of the end of the batton on both ends to line up.


STEP 5 - MAKING THE CHAIR - ASSEMBLY

4 of 4mm x 45mm

12 of 4mm x 75mm

To screw together start by attaching the back to one side then attach the seat. Next screw on the otherside and �nally attach the back rail making sure that you position it centrally to the screw hole in the rear leg.

Again it is important to align the parts prior to screwing together - start with one screw and if correctly placed, do the rest, if not loosen it a bit and reposition then put in one of the other screws to hold it. Then �x all screws.

Using the sandpaper / block plane put a radius on the corners that meet the seat and back. Sand all edges of the chair to remove sharp edges and risk of splinters. Sand edges to smooth.

DONE - you can now keep the chair as it is or apply a water based (acrylic) varnish or paint it, or paint some of it.


I hope this has been useful. Please use it as a guide. Feel free to alter / adapt and reinterpret.

PROJECT DISCLAIMER

Your safety is your own responsibility, including proper use of equipment and safety gear, and determining whether you have adequate skill and experience. Powertools, electricity and other resourcesused for these projects are highly dangerous, unless used properly and withadequate precautions, including correct safety equipment and proper environments. Use of the instructions and suggestions in the How to make a chair open source (Open chair) is at your own risk. The designer disclaims all responsibility for any resultingdamage, injury, or expense in the making of the project, or usage of the �nished articles thereafter. It is your responsibility to make sure that your activities comply with applicable laws, including copyright.

Anyone, except for industry and dealers (in their professional capacities), can use these designs for personal use. I ask those who construct these designs, and variations in particular, to send photographs via their personal websites, which can be accessed via www.jamestooze.wordpress.com

STEP 6 - CHANGE WHATEVER YOU WANT

how to make a chair open source (06-11) - jamestooze · safety equipment and proper environments....

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