Connecting 2x4 to a 2x4 using clamps

[Suzy]

Hi, I am new here and have a few questions.

We are building an outdoor patio set using this plan and are only building armless chairs, not the corner piece.

http://www.morelikehome.net/2011/06/our-new-outdoor-sectional.html

As you can see the seat top are a lot of 2x4's with 1/2" spacing between them.  We have two different kinds of clamps, neither of which makes it easy to connect the corners together.

We have a seat section, leg and support frame section built already, we will be putting it all together when the paint dries.  We have painted four coats on all the PT lumber boards so when it dries we will be open to finishing the project.

We did change the project a bit, such as making the back taller for more comfort when sitting back and adding some support boards to it as well.  We also made the chair legs shorter to accommodate the very deep cushions I will be making to sit on and lean back against and a lumbar support pillow as well.  This should be a very comfortable set when complete.

I need the boards to line up evenly so the seat surface is flat and am having a hard time doing that.  What can I do to make it more level?  It seems that although the boards are all 2x4's they are not all exactly the same in thickness.

I was able to get some photos but the system allows only three.

The seat back and back legs are to the right in the first pic of all the components for the chair.  We have to wait for the last coat of paint to dry before assembly and will need to do touch up once it is togther. 

Thanks

[Suzy]

My husband put the chair together and it looks great. 

Thanks Joe, we wouldn't save any shavings and we put the sanded and drilled shavings on the grass, spread out.  I'm not sure if that is a bad thing or not.  We use masks and eye gear when working with the wood.

Chalk paint is a definite mystery to me, but now that I know i can check it out online I will.  I think we will stick with the bright white we are using, once i make cushions the white should pop off the cover pattern.

Here is a pick of the lone chair with modifications to the original plan, higher back, added back supports for the cushions so they don't fall through.  We also shortend the legs to accommodate the 4" thick seat cushions I am making, this will be a total of 19" from the top of the cushion to the ground.   The second to the top backboard hits about the shoulders, and the bottom one hits about the  lumbar.

[Joe V Bolin]

Looks fabulous, Suzy.  It was a good idea to change the dimensions. 

I wouldn't worry too much about spreading the dust/shavings on the lawn as long you don't accumulate a lot of it.

Thanks for the update.

[Suzy]

Hi Everyone, the weather has changed with the humidity being much lower and good temperatures.  We have a cold front that is interrupting that but it will only last a few days.  I am so exited to get the rest of the patio chairs made.  Hopefully we can do the planters and side tables as well but we have other projects that need to be completed as well.  We will be making sliding drawer/shelves for the kitchen cabinets so I can fully utilize my base cabinets but that is another post I will start at another time.   :)

I am so exited about getting some new tools to help us with our projects too.  We just purchased the Kreg Forman Pocket Hole Machine, the face framing table and a couple of Automax Clamps.  I think this job is going to go much faster too and we are contemplating a paint sprayer.  Does anyone have any experience with those?

Woohoo, can't wait until the weather improves.

[Suzy]

Yay!, one project down another to go.  Since we completed the kitchen drawer/shelves it is time to complete our patio chairs and I am hoping we can beat the humidity in time to at least have one party on the patio.  I'm not sure we will be able to get the side tables and planters built in time but that could be a project for next fall.

[Suzy]

This is a slow process as there are 22 boards for each chair and all of them need a coat of primer and two coats of paint so they can withstand the outdoor environment and last a few years.  We are done with our second chair and have 6 to go.  Yay!