This project started in August 2025 when I started cutting-up my old hot tub for disposal. Before I got too far into, I had the idea that some of the molded seating areas could possibly be used as the basis for a chair. The section circled below became the starting point for this chair. (The full build blog is here.)
Shaping the section was a slow process that stretched out over the early part of the project. The challenge was taking an asymmetric shell with no good reference lines and trying to shape it into something that might pass as symmetric.
I went through three different designs for the base before I arrived at something I was pleased with. The final design was inspired by the legs and stretchers of a Vladimir Kagan lounge chair. The leg angles and the raised rear stretcher made a good model to follow to create the base for my shell chair. The shape and dimensions of the leg assemblies and stretchers required numerous refinements, keeping in mind seat height, seat angle, proportions, stability, and the intangible, "does it look right." This is the rough form of where I arrived. I liked how the seat shell floated above the base.
Everything was shaped and sanded prior to glue-up. The back of the seat shell was sanded semi-smooth. Before final assembly, it received a coat of shellac on the back, followed by a coat of matte poly.
The hot tub jets were repurposed to attach the shell to the front stretcher of the frame. The other two jets are just window dressing since they didn't fall near the rear stretcher. They proclaim the chair's origin. The shell was attached to the rear stretcher with a pair of inconspicuous flat head screws.
The base received a coat of Rubio Monocoat 2C in Cotton White followed by an application of Sheen Plus. Originally, this chair was slated to be an outdoor chair, but after all the work that went into it, I just couldn't follow through on that. Using Rubio ensures that it can only be used indoors. 😆
With the seat attached, the chair was complete. (With the exception of the planned thin cushion.)
Between a lot of interesting builds, this is your most interesting. Its own, distinct and special style and it looks great, has a good story - and by far the best legs in town!
"The good chair is a task one is never completely done with" Hans Wegner
having followed the blog it's very cool to see the final product. i agree about the chair base, very sexy design ! this was a very inspiring process from cut up tub to completed chair. now it's time for me to get in my my hot tub. water, not chair 😎
working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.
Fantastic chair, Ross! I like how you took a piece of material that was destined for the trash heap and used it as the basis for a beautiful, stylish work of functional art.
Thanks for all your kind comments, guys. This was an interesting departure from my usual projects in that the design had to be constrained to adapt to a pre-existing component. It had a very different feel than a fully-from-scratch project where everything can be variable. But, I'm pleased with how it turned out and grateful for all the complimentary feedback.
