MAKE THE LEGS.

The rounded leg bottoms help the sun lounger rest firmly on uneven surfaces.

1. Cut the legs (A) to length. To ensure uniform length, cut four 2 × 4s to about 13" in length. Clamp them together edge to edge and gang-cut them to final length (12") with a circular saw.

2. Use a compass to scribe a 3-1/2"-radius roundoff cut at the bottom corners of each leg. Make the roundoff cuts with a jig saw (photo A).Sand smooth.

CUT THE FRAME PIECES AND LEDGERS.

1. Cut the frame ends (B) and frame sides (C) to length. Use a jig saw to cut a 5"-wide, 1-1/2"-deep notch into the top edge of one frame end, centered end to end, to create a handgrip.

2. Cut the ledgers (D) to length. Measure 24" from one end of each ledger. Place a mark, then cut a l-1/4"-wide, 3/4"-deep notch into the top edge of each ledger, centered on the 24" mark. Smooth out the notch with a 1-1/2"-radius drum sander mounted on a power drill. (This mark will serve as a pivot for the back support.) Sand all parts and smooth out all sharp edges.

ASSEMBLE THE FRAME.

1. Attach the frame sides and frame ends to form a box around the legs, with the tops of the frame pieces 1-1/2" above the tops of the legs to leave space for the 2 × 4 slats. Fasten with glue and drive 2-1/2" deck screws through the legs and into the frame sides. Also drive screws through the frame ends and into the legs.

2. Attach the ledgers to the frame sides, fitted between the legs, using glue and 2-1/2" deck screws. Make sure the ledger tops are flush with the tops of the legs and the notches are at the same end as the notch in the frame.

TIP

For a better appearance, always keep the screws aligned. In some cases, you may want to add some screws for purely decorative purposes: in this project, we drove 1" deck screws into the backrest slats to continue the lines created by the screw heads in the lower lounge slats.

CUT AND INSTALL THE BACKREST SUPPORTS.

1. Cut the slide brace (J) to length. Position the slide brace between the frame sides, 24" from the notched frame end, fitted against the bottom edges of the ledgers. Glue and screw the slide brace to the bottom edges of the ledgers.

2. Cut the slide supports (I) to length. Position the supports so they are about 3" apart, centered below the notch in the frame end. The ends of the supports should fit neatly against the frame end and the slide brace. Attach with glue and drive screws through the frame end and the slide brace, and into the ends of the slide supports (photo B).

FASTEN THE SLATS.

1. Cut all the slats (E) to length. Use a straightedge guide to ensure straight cuts (the ends will be highly visible). Or, simply hold a speed square against the edges of the boards and run your circular saw along the edge of the speed square.

ASSEMBLE THE BACKREST SUPPORT FRAMEWORK.

The adjustable backrest is held in place by a small framework attached to the back braces. The framework can either be laid flat so the backrest lies flat, or raised up and fitted against the inside of the notched frame end to support the upright backrest.

1. Cut the back supports (G) to length. Clamp the pieces together face to face, with the ends flush. Clamp a belt sander to your work surface, and use it as a grinder to round off the supports on one end.

2. Cut the cross brace (H) to length. Position the cross brace between the back supports, 2" from the non-rounded ends. Attach with glue and drive 2-1/2" deck screws through the supports and into the cross brace.

3. Position the rounded ends of the supports so they fit between the ends of the back braces, overlapping by 2-1/2" when laid flat. Drill a 1/4" guide hole through the braces and the supports at each overlap joint.

4. Thread 1/4"-dia. × 3-1/2"-long carriage bolts through the guide holes, with a flat washer between each support and brace. Hand-tighten a washer and nylon locking nut onto each bolt end (see photo D).

INSTALL THE BACKREST.

APPLY FINISHING TOUCHES.

Sand all surfaces and edges (photo E) to eliminate slivers. Apply two coats of waterbased, exterior polyurethane for a smooth, protective finish. Or, use a primer and a light-colored exterior paint.