Building Chairs with Plywood
What's up, sawdust kings and queens! Today, I want to chat about how I built a pair of dining chairs without breaking the bank on expensive hardwood, i.e., using plywood. If you haven’t caught the video yet, feel free to check it out for a detailed walkthrough. But stick around here, too, because I’ll be spilling even more woodworking tips and tricks to help you knock this build out of the park.
Here, I’m going to dig into laminating your own plywood (yep, layers on layers), why that matters, and how it stacks up (pun intended) against hardwood. Plus, I’ll dive into the difference between Baltic birch plywood and your standard grade plywood—because not all sheets are created equal. So let’s get started.
Why Build Dining Chairs with Plywood?
First off, let’s talk plywood. It’s an incredibly versatile material, perfect if you want something sturdy and stylish but don’t want to shell out for pricey hardwood (although the cost has definitely increased over the past couple of years for Baltic birch). If you watched the plywood chair build on YouTube, you’ll remember it used Baltic birch plywood. I love it for its density, clean edges, minimal voids, and overall dimensional stability—a big perk when you’re building something that’s going to support body weight every day.
Advantages of Plywood Furniture
Wallet-Friendly
Let’s be real: plywood is typically WAY cheaper than hardwood if you’re building multiple chairs (because who wants just one seat at the dining table?). Saving on materials can add up.Good Dimensional Stability
Plywood’s layered construction means it’s less likely to warp or twist. This is a huge plus if you live in an area with fluctuating humidity. Being in Southeastern Virginia, humidity plays a huge role in how I build furniture.Convenient Large Panels
You can cut several chair components—like the seat, backrest, or even the legs—from a single or double sheet. Talk about efficiency. For this project, I was able to build each chair from one sheet of plywood. And you don’t have to create any panels either. So, you get to skip the milling and panel construction part altogether.
Drawbacks of Plywood Furniture
Appearance Isn’t Always Fancy
While you can find beautiful plywood (especially Baltic birch), it doesn’t have the same character as solid hardwood. Some folks love the layered edges, others prefer a more classic hardwood look.Visible Layers
If you don’t like seeing the “ply” edges, you’ll need to add edge banding or create a design that conceals them. I for one, think they look great in some cases, but that’s going to be your preference.
Baltic Birch vs. Standard Plywood
So, you’re standing in the lumber aisle, and you see both Baltic birch and domestic birch plywood. How do you choose?
Characteristics of Baltic Birch Plywood
More Plys (Layers): Often 9, 11, or even 13 layers in a 3/4-inch sheet. This makes it super sturdy and less prone to warping.
Fewer Voids: The core layers are usually solid with minimal gaps, so your screws hold tighter and your edges look better.
Flatter and Stronger: Less fussing around with warped boards, so you can get right to building.
Characteristics of Standard Birch Plywood
Fewer Layers: Generally fewer laminations, making it slightly weaker or more prone to small voids.
Cheaper: If you’re on a strict budget, you can still make it work.
Potential Voids: You might run into gaps in the core, which can be annoying when you’re drilling or cutting and cause structural issues.
In short, Baltic birch is typically the top choice for furniture projects, while standard birch is okay for less demanding builds or if you plan to paint or cover edges with banding.
Plywood vs. Hardwood: Quick Comparison
Looks: Hardwood has that classic, natural beauty with unique grain patterns. Plywood can look modern and sleek—especially when you embrace the layered edges or use a nice top veneer.
Price: Plywood is generally more cost-effective, which is perfect if you’re building multiple pieces.
Sustainability: Using plywood can be more eco-friendly if it’s from a responsible source, since it uses thinner layers of wood and less of the tree is wasted.
Working Process: Both hardwood and plywood can be cut, drilled, and sanded with standard woodworking tools. But plywood edges can sometimes chip or tear out if you’re not careful and you have to watch how much you work the surface as you can sand through the veneer.
How to Build a Plywood Chair
Laminating Two Sheets of Plywood
If you really want your dining chair to be rock-solid, laminating (a.k.a. gluing two sheets of plywood together) is a killer move. It doubles the thickness, making the chair seat and back super sturdy. It also helps reduce any annoying flex when you sit down.
Step-by-Step Guide to Laminating
Cut Your Shapes
Trace or mark out the shape of your seat and backrest on each sheet of plywood. Cut them slightly larger than needed—think 1/8-inch or so extra space on all sides—so you can trim them perfectly after laminating.Apply Quality Wood Glue
I personally love Titebond III for its strength and water resistance. Spread a thin, even layer on the entire surface of one sheet. This step is critical—don’t skimp on the glue!Clamp, Clamp, and Clamp Some More
Place the second sheet on top of the glued substrate and line up the edges. Then go to town with clamps. Use cauls (flat boards) on top and bottom to distribute pressure evenly. You want a nice, tight fit with zero gaps. Alternatively, you can check out the video and see how I used a vacuum press instead of the clamps to apply clamping pressure to the plywood.Let It Dry
Follow the glue’s recommended drying time (usually at least 24 hours for a full cure). Don’t rush this. Patience here pays off.
Tips and Tricks for Building Your Plywood Dining Chair
Plan Your Joints Carefully
If you’re attaching the legs to the seat, consider reinforcing with pocket holes, corner blocks, or additional support brackets. I used dominos but any joinery you can add for additional strength would be a good idea.
Try Bent Lamination
Want to get really fancy? Plywood is excellent for curved backrests or armrests. You can layer up thin sheets and bend them around a form. Check out this video on bent lamination!
Watch Out for Voids
If you’re using standard birch plywood, check edges for gaps and fill them with epoxy or wood filler before finishing.
Show Off Those Edges
Baltic birch layers can look fantastic if you round over or bevel the edge. It gives a cool, contemporary vibe to your chair. I added a round over to the dining chair's edges to show off those laminations. I think it adds some nice contrast to the dining walnut table they are sitting at, while the roundover compliments the roundedness of the table.
Finishing Touches
Don’t skip the finishing process—that’s what protects your chair from everyday wear and tear (and spilled drinks). If you used a high-grade Baltic birch:
Hard wax oils both protect the furniture and allow for the natural beauty of the lumber to shine.
A clear varnish or polyurethane can highlight that light, clean look.
For a pop of color, you can also use paints or stains. Just be sure to test on scrap pieces first because plywood can absorb finishes differently than hardwood.
And there you have it! Building a pair of plywood dining chairs is a fantastic way to explore new woodworking techniques without breaking the bank. By laminating two sheets of plywood, you get a stronger, thicker seat that can handle everyday use for years to come.
If you give this a try, I’d love to see your work. Feel free to drop a comment below or tag @TimberBiscuitWoodwork on Instagram. Happy building, friends—and keep on crafting!
