DIY Adirondack Barrel Footrest: A Step-by-Step Guide

by Barrel Blogger April 18, 2025

Create the perfect companion to your Adirondack chair with this stylish and comfortable footrest. Using repurposed barrel staves, this project combines rustic charm with practical design. Follow these detailed instructions to craft your own unique footrest.

Materials You'll Need:

8 barrel staves (various widths)
2 staves for legs and seat supports
1 crossbar (center stave cut)
5 seats (center stave cut)
28 #10-1 ¾” flat head screws
Stain
Oil

Tools Required:

Drill motor
#2 square screwdriver bit
7/32 drill bit (if holes aren't pre-drilled)
Clamps
Measuring tape
Pencil
Safety glasses
Sandpaper
Router (optional, for finishing edges)

Measurements:

Legs: 8-9” long (cut from the same stave as seat supports)
Seat Supports: 28-29” long (cut from the same stave as legs)
Crossbar: 14” inside leg dimension (crossbar is center stave cut)
Seat #1 (front): 19.5” long (seats are center stave cut)
Seat Supports (back end width): 13.75” inside stave dimension
Total seat width: 17-19” center down the seat support stave
Remaining support stave (sticking out): 11-12”
Width of last seat: approximately 16 7/8”
Spacing between seats (center): approximately 1.5”
Spacing between seats (ends): approximately 2”

Step-by-Step Instructions:

Prepare the Wood:

Sand all barrel staves to your desired smoothness. This ensures a comfortable finish and removes any rough edges.
Apply stain to all pieces. Choose a color that complements your Adirondack chair or matches your outdoor décor.
Once the stain is dry, apply oil to seal and protect the wood from the elements.

Assemble the Frame:

Attach the legs to the seat supports. Use two screws for each leg, driving them in from the top of the seat support. Ensure the legs are positioned correctly for stability.
Attach the crossbar to the legs. Position it 14” inside the leg dimensions and secure it with two screws per leg from the back.

Attach the Seats:

Hint 1: Before attaching the first seat, hold the front legs in their desired position and clamp the back end of the seat supports to the correct width. This ensures proper alignment.
Attach the 1st seat. Center it across the top front of the supports and secure it with screws.
Hint 2: Clamp and screw the 1st seat completely before moving on to the remaining seats. This provides a stable base for the rest of the assembly.
Precut the remaining seat staves according to the measurements, noting that the total seat width should be about 17-19” center down the seat support stave.
Hint 3: Re-clamp the back end of the supports to the desired width. Then, clamp the remaining seats in position from the top side.
Attach the remaining seats, spacing them approximately 1.5” apart at the center and 2” apart at the ends. Use two screws to attach each seat to the support on each side.
Flip the footrest over to screw the supports to the seats.

Finishing:

Once all seats are attached, you can use a router to smooth the top edges for a more refined look. This step is optional but enhances comfort and aesthetics.
Consider branding your footrest for a personal touch.

Tips for Success:

Accurate Measurements: Double-check all measurements before cutting to avoid errors.
Clamping is Key: Use clamps to hold pieces firmly in place while screwing. This ensures tight joints and prevents movement.
Pilot Holes: If your staves are hard, drill pilot holes for the screws to prevent the wood from splitting.
Consistent Spacing: Pay attention to the spacing between the seat staves for a uniform appearance.
Safety First: Always wear safety glasses when using power tools.

Enjoy your handcrafted Adirondack footrest! This guide provides the detailed steps and tips you need to create a beautiful and functional addition to your outdoor space.