Adjust the blade of the table saw to cut at a 45-degree angle. Adjust the blade height to cut through a 1/8-inch-thick material. Tighten the blade angle and height adjustment knobs in place.
Place each 1/8-by-18-by-18-inch fiberglass sheet flat on the table saw. Cut each 18-inch edge at a 45-degree angle on one side of each sheet, one at a time.
Sand the cut edges of the fiberglass sheets with a fine-grit sanding block until they are smooth.
Fit the six 1/8-by-18-by-18-inch fiberglass sheets together with the cut edges touching each other to form a cube. Apply epoxy to the adjoining cut edges and press the assembly together. Ask someone to help you hold the assembly while you clamp each end with a frame clamp.
Allow the epoxy to dry for 24 hours. Remove the frame clamps from each end of the the cube assembly. This is the base of the chair.
Place the 1/8-by-18-by-36-inch fiberglass sheet against one side of the cube. Orient the sheet vertically lengthwise. This is the back of the chair. Apply epoxy to the sheet where it adjoins with the side of the chair base. Clamp the sheet to the cube using the two frame clamps. Remove the clamps after 24 hours.
Things You Will Need
- Table saw
- 6 fiberglass laminate sheets, 1/8-by-18-by-18-inch
- Sanding block, fine-grit
- 2 frame clamps
- Fiberglass laminate sheet, 1/8-by-18-by-36-inch
- Add furniture pads to the bottom corners of the chairs if you have wood floors to protect them from scratches.