Plans to Build the Ashton Chair

An Easy to Build Chair Inspired by a Catalog Retailer

This beautiful chair is truly an easy build! Though the cuts in the plans to build the Ashton chair look complicated, they truly are not, and can be made using a jigsaw or a bandsaw. The only major requirements would be a sharp pencil, a straight edge and a pocket hole jig!

Most of the joints are assembled with the pocket hole jig and the rest use my favorite screws: Powerlags by Spax. The heads of these screws can be spray painted for a really cool look!

I have also included templates for the legs to make marking the cut lines a little easier. To use the templates, print them out AS-IS actual size (do not resize them in your printer software), align the registration marks, tape the sheets together, then cut out the template. If the templates are going to be reused, the pieces can be secured to posterboard using spray adhesive. For a tutorial on using a template, see this post!

Materials:

• 1-1/2″ pocket hole screws
• 2-1/2″ pocket hole screws (<– affiliate link!)
• 3″ Spax Powerlags (<– affiliate link! – a T30 drill bit is required)
• Wood glue
• Sandpaper (80, 120, 220 grits)
• Finishing supplies

Lumber:

• 2 – 2×2 at 8′
• 3 – 2×4 at 8′
• 1 – 2′ x 4′ sheet of 3/4″ plywood

Templates for the Legs

• Leg 1
• Leg 2

Cut List:

• 2 – 2×4 at 23-5/16″- Leg Assembly
• 2 – 2×4 at 24-9/16″ – Leg Assembly
• 2 – 2×4  at 27-1/2″ – Arm
• 2 – 2×4 at 21-1/2″ Seat Frame
• 5 – 2×2 at 22″ – Seat Frame
• 1 – 2×2 at 25″ – Seat Frame
• 1 – 3/4″ plywood at 16-1/4″ x 22″ – Back
• 1 – 3/4″ plywood at 20-1/2″ x 22″ – Seat

Notes About the Project:

• Draw all of the markings for cuts on the 2x4s before cutting
• Sand all pieces prior to assembly
• If spray painting the Powerlags, do so before assembly
• 24″ wide premade cushions can be used or you can make your own

Step One

Cut the pieces for the leg assemblies and arms to length. Trace the templates on the face of each leg piece – refer to the drawings for the dimensions and the straight edge of the board. Make the cuts using a jigsaw or a bandsaw.

Cut the pieces for the arms. The angle in the arms a just simple tapers and can be made using a tapering jig on a table saw. A router with a roundover bit can be used to soften the top edges of the arms (the straight edge of the pieces).

With the pocket hole jig set for 1-1/2″ material, drill pocket holes in the top edges of the leg assembly pieces as shown – THERE WILL BE A LEFT ASSEMBLY AND A RIGHT ASSEMBLY!

Step Two

Cut the 2×4 pieces for the seat frame, and draw the cut lines on the pieces. Make the cuts in the same manner as the pieces for the leg assemblies.

Cut the remaining pieces for the seat frame. Drill pocket holes in each end of the 22″ 2x2s. Assemble the frame as shown in the drawings, using glue and 2-1/2″ pocket hole screws. Make sure that the front faces of the 2x2s for the back are flush with the front of the angled 2×4 pieces.

Step Three

Cut the pieces of plywood for the seat and the back. Set the pocket hole jig for 3/4″ material and drill pocket holes in all four edges of each piece. Secure the plywood pieces to the frames using glue and 1-1/2″ pocket hole screws making sure that the top face of the plywood is flush with the frame.

Step Four

Draw a line on each side of the seat approximately 8-5/16″ from the front edge. Also draw a line on the front leg along the straight edge at 13-11/16″ from the bottom. These marks will align the seat/back frame with the leg assemblies. The seat/back frame should slope approximately 5° toward the back. Secure the leg assemblies to the seat/back frame using the 3″ Powerlag screws. There should be two Powerlags in each leg and two through each arm. The holes should be pre-drilled to avoid splitting the wood.

Finish as desired.

This chair is a great addition to the indoors as well as the outdoors when properly finished. Have questions about the plans to build the Ashton chair? Leave a comment below!