Stool Project

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Posted in WorkshopWoodworking

Introduction: Stool Project

Cut List:

  • 4 2 x 2 wood pieces, 32 inches each for the legs
  • 1 large 2 x 1 plank, was cut in half and then segmented into 8 inch pieces for horizontal supports
  • 20 1 x 1 triangular/angled pieces, used as additional support underneath the horizontal ones (a pair for each one and then extra for additional)
  • 1 large 15.75 in by 15.75 in MDF wood square plank for the seat
  • 1 18 in diameter MDF wood circle used as additional platform for storage at bottom

Materials:

  • Ruler
  • Pencil
  • Leveler
  • 1 inch screws
  • 1/2 inch screws
  • Sandpaper
  • Wood glue
  • spray paint (red, white, and black)
  • Pencil holders
  • Wood finish
  • 1 inch radius wheels

Machines/Tools:

  • Saw blade or band saw
  • CNC machine
  • Router Machine
  • Clamp
  • Drill

Step 1: Connector Piece

1. Cut 2x1 wood into 12 inch pieces. These wooden pieces will be used to connect the legs together.

2. For each 12 inch piece of wood, use either a drill or metal wedge to create an angled hole for the screw. It is important that the angled hole is not too close to the face edge of the piece of wood to preserve the integrity of the stool.

3. Create four of these angled holes per piece of wood. 2 on each end, 1 inch apart from each other.

4. Sand down each edge

Step 2: Getting the Legs

1. Cut 2x2 wood into four 32 inch length pieces. These are our legs for the stool.

2. Gather the four legs together and tape the legs together to form a 2 by 2 rectangular prism.

3. Sand down all four legs at the same time to even out the legs to prevent wobble.

4. After sanding, remove the tape and sand the face of the legs to smooth it out.

Step 3: Triangle Piece

1. Using 2x1 wood, measure out 1.5 inch squares on the wood. Be sure to leave space in between each square to account for wood loss from the saw blade or band saw.

2. Using a straight edge, draw a line through the square from one corner to the other corner to create 2 triangles out of each square. Repeat for each square.

3. [HAND SAW] Clamp the wood as depicted in the second picture down. Saw the triangles. Be sure to saw straight down in order to prevent cracking near the edges. Sand down the triangles to smooth out the surface

3. [BAND SAW] Cut the triangles out using the band saw. The cuts will come out cleaner but may still require sanding down to smooth out the surface.

4. These triangles are meant for both design and structural purposes, you may add additional triangles where you deem necessary.

Step 4: Leg Assembly

1. On a table surface, lay the leg horizontally down.

2. Place connector piece perpendicularly to the leg as shown in the picture. Place one connector piece up 7 inches from the ground and another connector piece down 9 inches from the top.

3. Drill 2 screws through the angled holes and into the leg piece for each connector piece.

4. Use wood glue to glue the wooden triangles on the underside of each connector piece. Allow the glue to dry

5. [OPTIONAL] You may put additional triangles on the top side of each connector piece, however this does not add significantly to the overall structural integrity of the stool.

Step 5: Connecting the Legs

1. After drilling the connector pieces into one of the legs, obtain another leg and place it parallel to the first leg.

2. Drill the connector pieces into the second leg. One connector piece 7 inches from the ground and another 9 inches from the top.

3. Glue triangles into the underside of the connector pieces and allow it to dry.

4. Repeat "Leg Assembly" twice and "Connecting the Legs" once more.

Step 6: Three of Four Legs

1. After repeating "Leg Assembly" twice and "Connecting the Legs" once more, the finished result should be like the two images above.

2. Place the three legs on the ground to make sure the legs are all even before drilling the fourth leg together.

Step 7: Center Disk

1. Obtain MDF panel and cut 9 inch radius disk using a CNC machine or band saw.

2. Measure out 1.25 inches on the disk from the radius and cut.

3. Measure out 1.25 inches, perpendicular to the first cut, and cut. The resulting shape is a square which will be used to fit into our legs.

4. Repeat steps 2 and 3 three more times to allow for the other legs to fit into the circle. The cuts are 12 inches apart from each other.

5. Rotate the disk into position. If it does not fit, then push one of the legs to allow give for the disk to fit in.

6. Once in position, repeat "Leg Assembly" and "Connecting the Legs" to finish the leg base.

Step 8: Leveling the Disk

1. After completing all four legs of the stool, level the disk using a leveler.

2. Once it is level, glue on triangles to the underside of the disk to support it.

3. Place 2 triangles on each leg to support the disk.

4. Allow for the wood glue to dry.

Step 9: Drilling the Triangles

1. Prepare pilot hole by using a drill bit and hand screwing a small indent in the wood. The intend of wood should be placed high enough so the screw can drill through both the triangle and the leg. Depending on your screw length, alter the height of the indent.

2. Use drill to continue pilot hole. Stop pilot hole drilling once you reach the leg.

3. Obtain screw and drill through the pilot hole and into the leg. Do not over-drill because you may risk cracking the triangle pieces.

4. Repeat for all triangles in the stool, given that the wood glue has sufficiently dried.

5. If the wood glue has not dried, refer to "The Top and Clamping Overnight"

Step 10: The Top and Clamping Overnight

[THE TOP]

1. Using MDF wood, cut out 15.25 by 15.25 square inch slab of wood.

2. Use router machine to trim the wood slab into a curved edge. Complete trim on all four edges.

3. Drill pilot hole into the slab of wood where the screw goes into the leg.

4. Drill screws through the pilot hole and into the legs.

[CLAMPING OVERNIGHT]

1. Obtain 4 clamps and clamp the disk to the bottom connector piece. Do not over-tighten.

2. Leave stool upside down overnight to allow for the glue to dry properly.

Step 11: Initial Testing

1. Once completed all previous steps, allow peers to test your stool.

2. Ask peers of different weights and heights to test the stool.

3. If told the stool wobbles too much, sand down the longest leg and even out the stool base.

4. Once satisfied yourself, move on to "Staining"

Step 12: Staining

1. Use masking tape to cover the diameter of the disk. Near the center of the disk, place down masking tape to cover a 2.5 inch radius circle. Also use masking tape for all parts of the stool that you not need to be stained.

2. Spray paint half of the stool red and the other half of the stool white.

3. Uncover circle masking tape without removing the rest of the masking tape on the diameter of the disk.

4. Spray paint the center circle white. Once dried, re-cover the white center circle and remove the masking tape in the diameter.

5. Use masking tape to cover the edges of the red and while borders on the disk.

6. Spray paint the newly uncovered area on the diameter black.

7. Remove all masking tape.

8. Use black marker to outline the white center circle to separate the white center circle from the red and white sides of the stool.

9. Allow for the stool to fully dry.

Step 13: Approval

1. Allow the school principal, janitors, and Chinese teacher to observe and comment on your stool.

2. Take picture with the school principal, janitors, and Chinese teacher as they give you their mark of approval for your stool.

Step 14: Drying Overnight

1. Bring stained stool indoors to allow for drying overnight.

2. Place warning label above stool indicating wet paint if in public area.

Step 15: Pencil Holders

1. Retrieve two metal mesh pencil cups.

2. Drill screw through the mesh lining and into the wood legs. Angle the screw in order to prevent rotation while in use.

3. Repeat on the other side.

Step 16: Wheels

[WHEELS ON BOTTOM]

1. Cut out 2 inch by 1 inch by 1 inch block of wood.

2. Drill two 1 inch screws in diagonal formation through the block of wood and into the bottom of the leg.

3. Drill wheel into block of wood using four 1/2 inch screws.

4. Repeat for each leg.

5. Refer to the first picture.

[WHEELS ON SIDE]

1. Drill wheel into the connector piece using four 1/2 inch screws.

2. Refer to the second picture.

Step 17: Enjoy Yourself

1. Don't forget to enjoy the stool you have created in any means possible, especially with friends!

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