In terms of furniture designs, a Pilates chair is similar to an ottoman. The chair consists of a wood base and sides with a padded seat and padded step. The step is hinged and springs provide resistance for certain exercises. Building your own Pilates chair affords options of a woodworking design and choice of colors for the seat and step coverings. A hardwood veneer can be finished with stain or clear sealer. Building a Pilates chair is not difficult for anyone with knowledge of woodworking. Basic hand and power tools are used to make the frame, attach the hardware and install the pads and coverings. A sketch or photo of the chair provides a reference guide.
Chair
Step 1
Set the fence on the table saw to 25 inches from the center of the blade to the inside edge of the fence. Rip a piece of 1/2-inch hardwood veneer plywood 25 inches wide and the full length of an 8-foot sheet. Use the framing square and circular saw to mark and cut two pieces 32 inches long from the 25-inch rip as sides for the base.
Step 2
Use the table saw to cut the remaining 32-inch portion of the ripped piece 20 inches wide as the bottom of the chair. Cut another piece of 1/2-inch veneer plywood 21 inches wide and 25 inches long as the back piece.
Step 3
Drill 1/4-inch countersink holes along one end of the sides and back piece. The countersinks should be 1/4-inch from the edge. Apply wood glue to the short edge of the bottom piece. Align the back piece with the bottom so you have 1/2-inch overhang at each end and attach it to the bottom using 1-inch brass wood screws with the electric drill and a screw tip. Apply glue to the ends of the side pieces, butt them against the overhanging edges of back and attach these to the bottom in the same way.
Step 4
Use a miter saw and cut two pieces of 1-inch-by-1-inch square hardwood stock 25 inches long as inside corner braces for the sides and back. Apply wood glue along two edges of the braces and attach them from the outside with 1-inch brass screws in 1/4-inch countersinks about 2 inches apart. Cut a piece of 1/2-inch veneer plywood 21 inches long and 16 inches wide as the top of the chair and use wood glue and 1-inch brass screws to attach it to the top edges of the sides and back piece.
Step And Pads
Step 1
Cut a piece of 1/2-inch veneer plywood 8 inches wide and 18 inches long as the step. Cut a piece of 1-inch square stock 15 1/2-inches long as a support. Flush the support with the long edge of the step, center the piece from end to end and attach it to the step using wood glue and 1-inch brass screws 2 inches apart.
Step 2
Cut two pieces of 1-inch square aluminum tubing 14 inches long as arms for the footrest. Drill 1/4-inch holes at each end of the pieces. The holes should be 1/4-inch from the ends and fully penetrate the tubing. Use nylon washers on each side of the arms and attach the arms to the ends of the step support with 3/8-inch lag screws and an open-end wrench.
Step 3
Position the free ends of aluminum arms against the sides on the inside of the chair. Maneuver the step in a swinging motion to determine where the arms should attach and mark these points on each of the sides. Drill 1/4-inch holes in the chair sides at the marked locations. Put nylon washers on each side of the arms and attach them to the sides with 3/8-inch carriage bolts and hex nuts. Insert the carriage bolts from the outside of the chair for a finished appearance.
Step 4
Attach 1-inch metal clips to each end of the step support using 1-inch screws and connect a 24-inch spring to each clip. Raise the footrest to its uppermost position, pull the springs horizontal and mark the location of the end of each spring. Drill 1/4-inch holes at the marked locations, Insert 3/8-inch carriage bolts and secure the springs with a washer and nut at each bolt.
Step 5
Use a utility knife and cut pieces of 2-inch foam padding to fit the seat and the step. Apply contact cement to the plywood veneer and set the pads in place. Cut pieces of vinyl upholstery fabric that covers each of the pads with enough excess to tuck a fold under at the edges. Staple the fabric at the plywood sides of the seat and step with a staple gun and 3/8-inch staples.
Tips and Warnings
- Select the springs based on a psi rating. Add outside corners or picture frame molding to highlight the design. Use sanding sealer before applying stain or clear coat.
Things You'll Need
- 1/2-inch hardwood veneer plywood
- Table saw
- Framing square
- Circular saw
- Electric drill or cordless drill
- 1/4-inch countersink bit
- Wood glue
- 1-inch brass wood screws
- Screw tip
- 1-inch-by-1-inch square hardwood stock
- Miter saw
- 1-inch square aluminum tubing
- Hacksaw
- 1/4-inch drill bit
- 3/8-inch lag screws
- Nylon washers
- Open-end wrench
- 3/8-inch carriage bolts with nuts
- 1-inch metal clips
- 1-inch stainless steel springs, 24 inches long
- 2-inch foam pad
- Utility knife
- Contact cement
- Vinyl upholstery covering
- Staple gun
- 3/8-inch staples
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