I started with chair design plans from Rockler. I cut the seat and back slats from 1 inch Select Pine and all of the frame pieces from 2 x 8 Pine stock. My first approach/attempt was to cut out patterns for all of the pieces and then use the router to cut out the final material - the Pine is not strong enough and large chunks would break away during the trim routing. I then used my Jig saw and sander to cut out and finish all of pieces. We painted the chairs in the same theme as our house.
See Rockler for available plans to purchase which have cardboard patterns.