Transform Your Space with the McHenry Double X Chair
Every time I share a new chair plan, I love to remind everyone how easy it is to build your own chairs! The McHenry Double X chair plan is just as simple and fun. Using some off-the-shelf lumber, you can easily whip up a few of these beauties over a weekend. So why not give chair building a shot? You might just discover a new favorite hobby!
Materials:
- 1-1/4″ pocket hole screws
- 2″ brad nails
- Edge banding (<– affiliate link!)
- Wood glue
- Sandpaper (80, 120, 220 grits)
- Finishing supplies: primer and paint or stain and sealer
Lumber (to build ONE chair):
- 1 – 1×2 at 8′
- 1 – 1×3 at 8′
- 1 – 2×2 at 4′
- 1 – 2×4 at 8′
- 1 – 2′ x 2′ sheet of 3/4″ plywood
Cut List:
- 2 – 2×4 at 40″ – Back Legs
- 2 – 2×2 at 17-1/4″ – Front Legs
- 2 – 1×3 at 14-1/2″ – Side Aprons
- 2 – 1×3 at 15″ – Front and Back Aprons
- 2 – 1×3 at 15″ – Back
- 2 – 1×2 at 14-1/2″ – Side Lower Bracing
- 1 – 1×2 at 15″ – Center Lower Bracing
- 4 – 1×2 at 6-11/16″ – Smaller Back X Detail Pieces
- 2 – 1×2 at 14-1/16″ – Longer Back X Detail Pieces
- 1 – 3/4″ plywood at 17-1/2″ x 18″ – Seat
Notes About the Project:
- Edge banding will be applied to the exposed edges of the seat before assembly
- Sand all parts before putting everything together
- A template is included for the back leg and the X detail for the back
Step One
Print out the template for the back leg. Align the registration marks on the sheets, tape them together, and then cut the template out. Secure the template to the 2×4 piece using low-tack spray adhesive, then cut using a jigsaw or bandsaw. Consider printing a few extras if you’re making more than one chair!
Pro tip: Cut both legs at once by stacking the two 2×4 pieces secured together with double-sided tape and cut as one piece!
Step Two
Cut the pieces for the front legs and the side aprons. With the pocket hole jig set for 3/4″ material, drill pocket holes in each end of the apron pieces. Secure the aprons to the front and back legs using glue and 1-1/4″ pocket holes. The inside faces of the aprons will be flush with the inside faces of the legs.
Don’t forget that there will be a right and a left assembly!
Step Three
Cut the pieces for the front and back aprons. Drill pocket holes in each end and secure to the front and back legs using glue and 1-1/4″ pocket hole screws. The inside faces of the aprons will be flush with the inside faces of the legs.
Step Four
Cut the pieces for the lower bracing and drill pocket holes in each end of the shorter 1×2 pieces. Secure the pieces to the lower portion of the legs, locating them 4″ up from the bottom.
Secure the middle bracing piece to the center using glue and 2″ brad nails through the outside.
Step Five
Cut the pieces for the back and drill pocket holes in each end. Secure to the upper portion of the back legs using glue and 1-1/4″ pocket hole screws. The front face of the back pieces will be flush with the front face of the legs.
Step Six
Print the template for the X detail. The templates should be used as a guide only, so double-check the measurements with the image below showing all dimensions. It may be best to cut the pieces a little long first, trimming as necessary, and then dry-fit the pieces on the back of the chair.
Drill the pocket holes in the ends as shown. Secure the longer pieces from the center diagonally to the outer edges of the back pieces with 1-1/4″ pocket hole screws. A close quarter drill attachment (<– affiliate link!) may be necessary.
Step Seven
Cut the piece for the seat and cut the notches with a jigsaw or bandsaw. Secure the seat to the frame using glue and 2″ brad nails.
Fill the pocket holes, then finish the chair as desired.
Have questions about the plans to build the McHenry chair? Leave a comment below!
