I'm starting to build an outdoor project based on some plans I found, which require 4x4 lumber for the legs and armrests. I'm curious if it's possible to router out some material from the 4x4s to lighten the overall weight without compromising their strength.
2 Answers
You might want to look for a different design that doesn't rely on 4x4 material. Working with that size can be pretty cumbersome and may make it harder to manage. In fact, using 2x lumber can often be sufficient for furniture without overbuilding it.
I strongly advise against routing out the 4x4s for outdoor use! Creating hollows can trap water, leading to potential rot over time. Thicker lumber is typically used outdoors because it resists deterioration at the surface, which is crucial for longevity.
I didn't even think of that, but you make a really good point. I guess I'll just stick with the heavy furniture.