Category: 3-4 hour assembly

Two by Two Chair

Ian Anderson

Two by Two DIY Chair by Ian Anderson
Two by Two Chair

Design and photography by Ian Anderson
Published in Fall 2019

The Two by Two Chair ambitiously utilizes a webbing system to form its seating surfaces. The builder is required to stretch and nail in each strap so that there is no slack when the chair is complete. Its shape is reminiscent of Rietveld chair designs, but it makes some ergonomic concessions learned from more modern chairs, where the back support cradles ones lower back with minimal pressure. The full assembly process takes a little over 3 hours to complete and the parts cost 50 USD on average.

Two by Two DIY Chair by Ian Anderson
Two by Two DIY Chair by Ian Anderson
Two by Two DIY Chair by Ian Anderson
Two by Two DIY Chair by Ian Anderson
Assembly

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1     Using a square tool and tape measure, measure and mark these lengths of wood: 2 pieces 29.5in (75cm) long, 4 pieces 18in (46cm) long, 3 pieces 19in (48cm) long, 1 piece 16in (39cm) long.
1     Using a square tool and tape measure, measure and mark these lengths of wood: 2 pieces 29.5in (75cm) long, 4 pieces 18in (46cm) long, 3 pieces 19in (48cm) long, 1 piece 16in (39cm) long.
2     Elevate the wood above the table and make cuts according to your measurements with the hand saw. Sand any rough edges of the wood after.
2     Elevate the wood above the table and make cuts according to your measurements with the hand saw. Sand any rough edges of the wood after.
3     Arrange two 19in (48cm) long pieces horizontally and two 18in (46cm) long pieces vertically on top.
3     Arrange two 19in (48cm) long pieces horizontally and two 18in (46cm) long pieces vertically on top.
4     Using a spare piece of wood as a spacer, make sure the 19in (48cm) long pieces extend under the 18in (46cm) long pieces by one full width of wood. Also, the 18in (46cm) long pieces should hang over the 19in (48cm) long pieces on the top corners.
4     Using a spare piece of wood as a spacer, make sure the 19in (48cm) long pieces extend under the 18in (46cm) long pieces by one full width of wood. Also, the 18in (46cm) long pieces should hang over the 19in (48cm) long pieces on the top corners.
5     In the upper corner, using the square tool, confirm the pieces form a 90 degree angle, and drill two diagonal holes where they overlap. Drill countersink holes, wide enough the screw can be embedded in them, about 1/2in (1.5cm) deep.
5     In the upper corner, using the square tool, confirm the pieces form a 90 degree angle, and drill two diagonal holes where they overlap. Drill countersink holes, wide enough the screw can be embedded in them, about 1/2in (1.5cm) deep.
6     Twist in two screws to join the pieces.
6     Twist in two screws to join the pieces.
7     Repeat steps 5-6 on the other upper corner.
7     Repeat steps 5-6 on the other upper corner.
8     On the bottom 2 corners, repeat the process in step 5, drilling and countersinking holes.
8     On the bottom 2 corners, repeat the process in step 5, drilling and countersinking holes.
9     Cut (and seal the ends with a lighter) a 22.5in (57cm) length of polyester webbing. Fold one end under itself and nail that end down over the holes of the still unattached 19in (48cm) long piece from step 8.
9     Cut (and seal the ends with a lighter) a 22.5in (57cm) length of polyester webbing. Fold one end under itself and nail that end down over the holes of the still unattached 19in (48cm) long piece from step 8.
10     Repeat step 9 on the other end of the 19in (48cm) long piece. Place the previously assembled pieces back in place, and while placing a lot of pressure on where the pieces overlap, add 4 screws into the previously drilled holes, through the webbing, and into the holes on the 19in (48cm) long piece.
10     Repeat step 9 on the other end of the 19in (48cm) long piece. Place the previously assembled pieces back in place, and while placing a lot of pressure on where the pieces overlap, add 4 screws into the previously drilled holes, through the webbing, and into the holes on the 19in (48cm) long piece.
11     Stretch the webbing across the frame, fold the other end of the webbing underneath itself, push a nail through the end, and prepare to drive the nail in. The strap must be very tight on the frame, so use the nail to lever the strap tighter before driving it in.
11     Stretch the webbing across the frame, fold the other end of the webbing underneath itself, push a nail through the end, and prepare to drive the nail in. The strap must be very tight on the frame, so use the nail to lever the strap tighter before driving it in.
12     Drive the nail in.
12     Drive the nail in.
13     Add 4 more nails, and repeat the process in steps 11-13 to secure the other strap.
13     Add 4 more nails, and repeat the process in steps 11-13 to secure the other strap.
14     Position two 18in (46cm) long pieces vertically at the lower corners of the frame.
14     Position two 18in (46cm) long pieces vertically at the lower corners of the frame.
15     Drill two diagonal holes, countersink, and add two screws to join the pieces. Repeat on the other 18in (46cm) long piece.
15     Drill two diagonal holes, countersink, and add two screws to join the pieces. Repeat on the other 18in (46cm) long piece.
16     Repeat the process in step 15, but on the inside of the frame. The 18in (46cm) long pieces should each be secured to the frame by 2 pieces of wood and 4 screws.
16     Repeat the process in step 15, but on the inside of the frame. The 18in (46cm) long pieces should each be secured to the frame by 2 pieces of wood and 4 screws.
17     Lay down 29.5in (75cm) long pieces vertically and one 16in (39cm) long piece horizontally between them.
17     Lay down 29.5in (75cm) long pieces vertically and one 16in (39cm) long piece horizontally between them.
18     Join each 29.5in (75cm) long piece to the 16in (39cm) long piece with 2 screws each.
18     Join each 29.5in (75cm) long piece to the 16in (39cm) long piece with 2 screws each.
19     Place a 19in (48cm) long piece 4.5in (12cm) from the top of the top of the piece in step 18.
19     Place a 19in (48cm) long piece 4.5in (12cm) from the top of the top of the piece in step 18.
20     Drill 2 holes, countersink, and add 2 screws on each end to secure the 19in (48cm) long piece 4.5in (12cm) from the top of the top of the piece in step 18.
20     Drill 2 holes, countersink, and add 2 screws on each end to secure the 19in (48cm) long piece 4.5in (12cm) from the top of the top of the piece in step 18.
21     Cut (and seal the ends with a lighter) nine 16.5in (41cm) lengths of polyester webbing. Nail one end of each of the 9 straps, evenly spaced, to the 16in (39cm) long piece. If you are using 2in (51mm) wide straps, you only need 7 straps.
21     Cut (and seal the ends with a lighter) nine 16.5in (41cm) lengths of polyester webbing. Nail one end of each of the 9 straps, evenly spaced, to the 16in (39cm) long piece. If you are using 2in (51mm) wide straps, you only need 7 straps.
22     Stretch the straps across the frame, and secure them in place using the method from step 11.
22     Stretch the straps across the frame, and secure them in place using the method from step 11.
23     Position the frame from the previous step so that the top of the seat measures 18in (46cm) from the bottom of the 29.5in (75cm) long pieces.
23     Position the frame from the previous step so that the top of the seat measures 18in (46cm) from the bottom of the 29.5in (75cm) long pieces.
24     Drill two diagonal holes, countersink, and add two screws to secure the 29.5in (75cm) piece to the 19in (48cm) piece on the seat frame. Repeat on the other side.
24     Drill two diagonal holes, countersink, and add two screws to secure the 29.5in (75cm) piece to the 19in (48cm) piece on the seat frame. Repeat on the other side.
25     Drill two more diagonal holes, countersink, and add two more screws to secure the 29.5in (75cm) piece to the 18in (46cm) piece on the seat frame. Repeat on the other side.
25     Drill two more diagonal holes, countersink, and add two more screws to secure the 29.5in (75cm) piece to the 18in (46cm) piece on the seat frame. Repeat on the other side.
26     Using the method from steps 11-13, add 7 more 25in (64cm) straps parallel to the existing 2 on the seat. Then, thread two 26in (66cm) straps across the 9 seat straps. If you are using 2in (51mm) wide straps, you only need to add 5 straps parallel to the 2 existing on the seat.
26     Using the method from steps 11-13, add 7 more 25in (64cm) straps parallel to the existing 2 on the seat. Then, thread two 26in (66cm) straps across the 9 seat straps. If you are using 2in (51mm) wide straps, you only need to add 5 straps parallel to the 2 existing on the seat.
27     Tighten the 26in (66cm) straps and nail to the underside of the seat at each end.
27     Tighten the 26in (66cm) straps and nail to the underside of the seat at each end.
Index
Parts
Smooth Planed Pine Wood, 2in x 2in (44mm x 44mm)
*Any popular softwood can also be used, like Redwood. Metric measurements above are actual, not nominal, and availability may vary by location.
 
Quantity required: 2 pieces 29.5in (75cm) long, 4 pieces 18in (46cm) long, 3 pieces 19in (48cm) long, 1 piece 16in (39cm) long
Flat Head Wood Screws, #6 x 2in (4 x 50mm)
 
Quantity required: 32
Polyester Webbing, 1.5in (38mm) Wide
Quantity required: 41ft (12.5m)
Wide Head Wire Nail, 3/4in (roughly 20mm) Length
 
Quantity required: 200
Tools
Hand Saw
Power Drill
Drill Bits
Ruler or Tape Measure
Screwdriver
Hammer
Square (or flat object with 90 degree angle)
Alternative Parts
Polyester Seatbelt Webbing, 2in (51mm) Wide
Quantity required: 36ft (11m)
Replaces: Polyester Webbing, 1.5in (38mm) Wide
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DIY Chair

Max Lamb

DIY Chair by Max Lamb
DIY Chair

Designed by Max Lamb
Published in Fall 2019

A DIY chair’s instructions are just as significant as the design of the DIY chair itself. The DIY Chair by Max Lamb, designed in 2008, is one of the more modern DIY chairs around, mainly because of the way Max chose to communicate the process of making the chair. The simple step-by-step method that he employed meticulously controls the process of production with detailed notes. The simple but time consuming assembly process takes up to 4 hours to complete. Parts cost under 50 USD on average.

DIY Chair by Max Lamb
DIY Chair by Max Lamb
Assembly

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1     Measure a length of wood at 18.5in (47cm) long and mark a line with your square tool.
1     Measure a length of wood at 18.5in (47cm) long and mark a line with your square tool.
2     Elevate the wood from the table and saw along the line you just made. Repeat step 1 and 2 until you have 30 pieces (31 pieces if using 18mm x 34mm wood).
2     Elevate the wood from the table and saw along the line you just made. Repeat step 1 and 2 until you have 30 pieces (31 pieces if using 18mm x 34mm wood).
3     Sand the rough edges and paint the pieces at this time if you would like. If painting, apply 2-3 light coats.
3     Sand the rough edges and paint the pieces at this time if you would like. If painting, apply 2-3 light coats.
4     Place two pieces of wood at a right angle with the wide side on top of the narrow side. The wide piece should hang over the narrow piece by 1 full width of wood.
4     Place two pieces of wood at a right angle with the wide side on top of the narrow side. The wide piece should hang over the narrow piece by 1 full width of wood.
5     Use the square to confirm a 90 degree angle, hold the two pieces down, and drill two vertical holes beside each other.
5     Use the square to confirm a 90 degree angle, hold the two pieces down, and drill two vertical holes beside each other.
6     Using a larger drill bit, countersink the holes. Then screw the two pieces together with wood screws until the screw heads are flush with the wood.
6     Using a larger drill bit, countersink the holes. Then screw the two pieces together with wood screws until the screw heads are flush with the wood.
7     Position the lower piece to be vertical. Place a third piece on top of the horizontal piece, and aligned with the edge of the vertical piece. Drill and screw the pieces together.
7     Position the lower piece to be vertical. Place a third piece on top of the horizontal piece, and aligned with the edge of the vertical piece. Drill and screw the pieces together.
8     Drill and add two more screws, through the wide side of the vertical piece, forming a triangular form secured with 6 screws.
8     Drill and add two more screws, through the wide side of the vertical piece, forming a triangular form secured with 6 screws.
9     Similarly to the process in step 5, 6, 7, and 8, secure two more pieces of wood at the end of the third piece.
9     Similarly to the process in step 5, 6, 7, and 8, secure two more pieces of wood at the end of the third piece.
10     Secure a sixth piece at the ends of the two parallel horizontal pieces. It should hang over each horizontal piece by 1 full width of wood.
10     Secure a sixth piece at the ends of the two parallel horizontal pieces. It should hang over each horizontal piece by 1 full width of wood.
11     Add two more legs to the frame.
11     Add two more legs to the frame.
12     By this stage, you should have a square frame with four legs.
12     By this stage, you should have a square frame with four legs.
13     Turn the frame over, and using one length of wood as a measuring spacer, secure a piece of wood parallel to the edge of the frame. Drill and screw each end.
13     Turn the frame over, and using one length of wood as a measuring spacer, secure a piece of wood parallel to the edge of the frame. Drill and screw each end.
14     Repeat step 13 for seven (eight if using 18mm x 34mm wood) more times.
14     Repeat step 13 for seven (eight if using 18mm x 34mm wood) more times.
15     Turn the frame over. There should be a gap left open on the seat.
15     Turn the frame over. There should be a gap left open on the seat.
16     Lay out another square frame with four wood pieces. Two parallel pieces on their narrow edge, and on top of them two parallel pieces on their wide edge.
16     Lay out another square frame with four wood pieces. Two parallel pieces on their narrow edge, and on top of them two parallel pieces on their wide edge.
17     The top pieces should overlap by 1 full width of wood.
17     The top pieces should overlap by 1 full width of wood.
18     Check that all corners form right angles, and join the pieces together with eight screws.
18     Check that all corners form right angles, and join the pieces together with eight screws.
19     Slide the new frame up the old one, positioning it 4 widths of wood below the seat base. Drill and screw two screws through each wide edge of wood.
19     Slide the new frame up the old one, positioning it 4 widths of wood below the seat base. Drill and screw two screws through each wide edge of wood.
20     This will secure the new frame to the old one using 16 screws total, 4 per corner.
20     This will secure the new frame to the old one using 16 screws total, 4 per corner.
21     To assemble the backrest, make a right angle with two wood pieces, as in step 4. The wide piece should hang over the narrow piece by 1 full width of wood.
21     To assemble the backrest, make a right angle with two wood pieces, as in step 4. The wide piece should hang over the narrow piece by 1 full width of wood.
22     Drill two holes, countersink the holes, and screw the pieces together. As in step 21, place a second piece at the other end of the upper piece. Drill and screw in place.
22     Drill two holes, countersink the holes, and screw the pieces together. As in step 21, place a second piece at the other end of the upper piece. Drill and screw in place.
23     Using the narrow side of a spare piece of wood as a spacer, place another horizontal piece across the narrow edges of the lower pieces.
23     Using the narrow side of a spare piece of wood as a spacer, place another horizontal piece across the narrow edges of the lower pieces.
24     Align with the edge of the first top piece, hold the wood in place, then drill and countersink two holes on each end of the piece you placed in step 23.
24     Align with the edge of the first top piece, hold the wood in place, then drill and countersink two holes on each end of the piece you placed in step 23.
25     Screw the piece in place at both ends.
25     Screw the piece in place at both ends.
26     Repeat steps 23-25, securing two more pieces. The backrest should have four pieces running perpendicular to two pieces holding them in place.
26     Repeat steps 23-25, securing two more pieces. The backrest should have four pieces running perpendicular to two pieces holding them in place.
27     Turn the backrest on its side, and place a piece of wood beneath the lowest of the 4 slats. With 2 screws, secure it to the piece running perpendicular to the 4 slats.
27     Turn the backrest on its side, and place a piece of wood beneath the lowest of the 4 slats. With 2 screws, secure it to the piece running perpendicular to the 4 slats.
28     With 2 more screws, secure the piece you added in step 27 to the lowest of the 4 slats.
28     With 2 more screws, secure the piece you added in step 27 to the lowest of the 4 slats.
29     Repeat steps 27-28, securing another piece of wood on the other side of the backrest.
29     Repeat steps 27-28, securing another piece of wood on the other side of the backrest.
30     Turn the chair frame in its side, place a piece of wood parallel to the front leg (opposite of the leg near the seat gap). Secure to the upper frame with 2 screws.
30     Turn the chair frame in its side, place a piece of wood parallel to the front leg (opposite of the leg near the seat gap). Secure to the upper frame with 2 screws.
31     Secure to the lower part of the frame with 2 more screws. The bottom of the piece you secured should be positioned no lower than the lower part of the frame.
31     Secure to the lower part of the frame with 2 more screws. The bottom of the piece you secured should be positioned no lower than the lower part of the frame.
32     Repeat step 30-31 with another piece of wood on the opposite side of the frame.
32     Repeat step 30-31 with another piece of wood on the opposite side of the frame.
33     Slide the back of the chair in place through the seat gap. Lean the back rest as far back as it will go, and align the arms with the top of the arm supports.
33     Slide the back of the chair in place through the seat gap. Lean the back rest as far back as it will go, and align the arms with the top of the arm supports.
34     Join the backrest to the inside of the frame using 2 screws on each side.
34     Join the backrest to the inside of the frame using 2 screws on each side.
35     Join the arms to the arm supports with two screws on each side.
35     Join the arms to the arm supports with two screws on each side.
Index
Parts
Smooth Planed Pine Wood, 1in x 2in (18mm x 34mm)
*Any popular softwood can also be used, like Redwood. Metric measurements above are actual, not nominal, and availability may vary by location.
 
Quantity required: 30 pieces, 18.5in in length (31 pieces, 47cm in length, if using 18mm x 34mm wood)
Flat Head Wood Screws, #6 x 1-1/2in (4 x 35mm)
 
Quantity required: 124
Tools
Hand Saw
Power Drill
Drill Bits
Ruler or Tape Measure
Screwdriver
Square (or flat object with 90 degree angle)
Sandpaper, 180 Grit
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