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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
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.03
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
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.04
450
420
380
350
400
310
450
420
380
PART A
*100 angle on one end
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.05
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
part quantity width length
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
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.06
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
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.07
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.
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.08
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.
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.09
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
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.10
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.
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.11
STEP 4 - MAKING THE CHAIR - SEAT + BACK
I 1 180mm x 380 mm
J 1 420 mm x 380 mm
part quantity width length
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.
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.12
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.
OPEN CHAIR - by James Tooze This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.13
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