This chair is made from the same templates as the Green New Yankee Workshop chair but made from structural (recycled) plastic. The plastic is very easy to machine. I routed the edges but didn't sand or glue.
Nice look!, I was reading about the plastic lumber and actually caught my attention because it look like ideal specially for exterior furniture. One concern was the "somehow more flexible than regular wood". Can you comment on this issue?
Also, what kind of hardware (srcrews) and glue (if any) did you use to build the chair?
Would you mind sharing the address or web of your supplier?
Thanks, Tango. The plastic lumber was more "springy" than natural wood but I think it will hold up. I used the same bolts and Bugle Head screws called out in the plans and what I used for the pine version. I didn't use glue which I was uncomfortable with but it seems to be holding up under light use. Following are some advantages and disadvantages of the plastic lumber:
1. Machines like butter. It was very easy to cut and since there is no grain I didn't experience any tearout.
2. Obviously, plastic lumber holds up better to the weather. That's important for those who live in harsh environments; northern and southern latitudes. It is also has UV inhibitors. How holds its color over time is TBD. The material has a 50 year guarantee.
3. No painting!
4. No sanding! The surfaces are not perfectly smooth but certainly doesn't feel unfinished, especially with edges rounded.
1. Availability. I had to work at getting this material and what I got were production trainings - not my choice of colors.
2. Gluing. As I mentioned above, I didn't glue my prototype. I was told by the manufacturer that epoxy wouldn't work.
3. Saw dust. It was summer when I made the chair and I had the garage door open. Saw dust floated out into the yard.