The One-Board Chair: A Timeless Design Project

Objective:

Students will learn fundamental woodworking skills by constructing a sturdy and portable chair from a single piece of lumber. They will practice measuring, marking, and cutting, while also learning about tool safety and the history of practical design.

Background:

This chair has a fascinating, if debated, history. Some say it was used by Mountain Men in the 1700s, while others trace it back to the Medieval era. We know for sure that it became popular in early 20th-century Boy Scout camps. Regardless of its origin, the chair is known for being comfortable, durable, and easy to store, making it a fantastic and long-lasting project.

Materials:

• One 2" x 12" x 8' board (This is a standard size, typically used for headers or decking).

Procedure:

1. Safety First!

Before starting, everyone must put on their safety glasses. All power tools must be used with adult supervision. Only one person should be operating a saw or drill at a time. Keep your hands and fingers clear of the cutting line at all times.

2. Cut the Back Board

Using the circular saw, measure and cut off a 48-inch piece from the 8-foot board. This will be the back of the chair. Set it aside for now.

3. Cut the Butt Board

You should have a longer piece of wood remaining. Measure and cut this piece to a length of 45 inches. This will become the seat and legs of the chair.

4. Create the Slots

This step requires careful measuring. The goal is to cut two long, narrow slots out of the butt board.

• First, measure 12 inches in from one end of the butt board and draw a line across. This line marks the front of the seat.

• Next, make two marks on that line, 2 inches in from each side of the board.

• Now, measure 33 inches down from the first line and make two more marks, also 2 inches in from each side.

• Use your long straight edge to connect the marks, creating two long, parallel lines. These lines will be your cutting guides.

• With adult supervision, use the circular saw to cut along these lines. You may need to finish the cuts with a hand saw in the corners. You will now have a U-shaped piece with a 33-inch slot in the middle.

5. Create the Back Board Slot

Now, take the back board you set aside earlier. We need to create a slot for the butt board to fit into.

• Measure up 11 inches from the bottom of the back board and draw a line. This is the bottom of your slot.

• Using one of the scrap pieces you just cut from the butt board, mark the width of the slot on the back board, centered on your line. This ensures a perfect fit.

• Using your drill, create a hole inside the marked slot area. This hole will be big enough to drop the jigsaw blade into.

• Carefully use the jigsaw to cut out the slot. It's better for the slot to be a little too big than a little too small.

6. Test Fit & Finish

• Try to fit the two pieces together. They should slide into each other to form the chair. If the fit is too tight, use the jigsaw to slowly trim a little more from the slot in the back board until it fits.

• Optional: Trim the corners of the seat and back boards by 1 inch to give the chair a more finished look.

• Finishing: Once the chair is assembled, you can sand the edges, paint it, or apply a stain or protective sealant.