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Make Adirondack chair templates out of plans

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Make Adirondack chair templates out of plans
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Some days ago I bought full size Adirondack chair plans. These wooden chairs come from Canada, and they are very nice and comfortable. These garden chairs are also known as Muskoka chairs, and some months ago I made my own version (watch the video here) out of pallet wood. And some years ago, before I start my YouTube channel, I made some from plans I had found in the Internet. Now, finally I found those plans once again, and to use them as many times as I want, first I will use them to make the Adirondack chair woodworking templates.

Sure you can find lots of Adirondack or Muskoka chair plans, but this is the nicest I could ever seen. At the end of this post you can find a link to buy these cheap plans.

Instructions to assemble the Adirondack chairIn this Adirondack chair plans we can also find some instructions about how to assemble the chair. But anyway, it in another video, and in another post, I will show how to use the woodworking templates to make the parts of this garden chair, and how to assemble it.


Good quality phenolic plywoodSo far, to make the woodworking templates I bought a good quality phenolic plywood board. This one is 1cm thick.


Now, first I cut the paper plans. So, I cut the pieces at half centimetre from the line. And I use spray stencil adhesive to stick the paper pieces to the phenolic plywood board. But there are two big pieces with long straight lines, so in those pieces I cut right against the line. And I put that edge of the big paper pieces right against the edge of the phenolic plywood board.

I use stencil adhesive to stick the plans to the plywood
I put the big pieces in the edge of the plywood

And now I use the jigsaw to cut the plywood pieces to make the woodworking templates. But because it would be very difficult to make clean and precise cuts, I cut at some millimetres from the lines. And later I will use my homemade sanders to adjust the dimensions of the Adirondack chair templates.

Use a jigsaw to cut the plywood pieces
Leave some millimetres between the cut and the lines

Precut the Adirondack chair templates. Don't cut the linesAs I mentioned before, I cut at some millimetres from the lines. And to make sure I never cut the line, sometimes I leave up to half centimetre between the line and the cut. But the main problem is that because stencil adhesive is not very hard, sometimes the paper peels off and the jigsaw blade breaks it. So in those cases I must pay attention so I don’t cut the line.


All the Adirondack chair templates that I get from the plansAfter cutting all the plywood pieces I still have a lot to do, because I must adjust the templates dimensions making sure the pieces are as perfect as the drawings in the original plans. So, I must sand them until I reach the lines in the paper.


Use the drum sander to adjust the concave curves up to the lineThen, first I will use my homemade drill press drum sander. And I will sand the inside or concave curves until I reach the line. I must be patient and work slowly. And if the paper moves up, I must move it down to see how much I sand.

Furthermore, I must press gently against the drum sander, and at the same time I move the workpiece to one side. Like that I’ll get a continuous surface, with no bumps.

But I don’t use the drill press drum sander to drill up to the straight lines. I leave something like 2 millimetres before I reach the straight lines. This is because it will be easier to adjust the straight lines in the drill powered disc sander. And I do the same with the outside or convex curves. In these cases I use the drum sander just to get close to the lines. But I don’t reach the lines.

Don't sand the straight edges up to the line in the drum sander
Don't sand the convex curves up to the line in the drum sander

Use the disc sander to adjust the convex curves up to the lineSo I will use my homemade drill powered disc sander to finish adjusting the Adirondack chair templates. All I have left to do is to adjust the straight edges and the convex curves. And regarding to the convex curves, they are quite easy to adjust using the disc sander.


Adjust the straight edges of the templates in the disc sanderBut it is not that easy to adjust the straight edges. And, if we have great Adirondack chair plans, but we make bad templates, we’ll have a lot of trouble when making the chair.

My trick is to sand in the edge of the sanding disc. I don’t press in the centre of the disc, so I leave a very small angle between the workpiece and the sanding disc.

Finally I move the workpiece, pushing slightly against the sanding disc, from the left to the right. Like that I try to get a straight and flat edge.

Adirondack chair templates finnished

All I have left to do is to sand the burrs using a foam sanding block. And like this I have finished these woodworking templates, and I can use them to make as many Adirondack chairs as I want.

You can buy here the plans to make this Adirondack chair.

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