This project was built and designed by Stan Sullivan from Simply Easy DIY. It’s a straightforward and practical step stool build that offers the perfect balance of utility and woodworking fundamentals.
Ideal for beginners and experienced woodworkers alike, this project introduces key skills such as material prep, layout, shaping, and joinery—all while creating a functional piece that’s useful in any home.
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A Practical Project with Lasting Value
A step stool may seem simple, but it’s one of the most helpful additions to any living space. Whether you need a little extra height to reach upper cabinets or want something sturdy for the shop, this build gets the job done—and looks great doing it.
Stan’s design includes a convenient cutout handle and thoughtful shaping that make the stool easy to move, store, and use. It’s a great opportunity to practice precision work without the pressure of a complex build.
Gathering Materials and Tools
While specific measurements aren’t included in this summary, Stan builds the stool using durable hardwood, which offers strength and visual appeal. The handle and edges are rounded and smoothed for comfort and safety.
Tools used in the build include a thickness planer, table saw, bandsaw, and clamps. Optional items like carpet tape and a router enhance accuracy and design detail, but the core steps can be done with standard shop tools.
Preparing the Lumber
The project starts with selecting solid stock and prepping it to final thickness. A planer ensures a smooth, uniform surface, while the table saw squares one edge and cuts pieces to width.
Stan emphasizes clean, accurate prep work here—because consistent material sizing leads to cleaner joints and a better-finished product. With a solid base, the layout and cutting go much more smoothly.
Laying Out the Shape
Instead of using digital templates, Stan lays out the design by hand. This approach adds a personal touch and allows room for slight variations that make each piece unique.
Measurements are marked directly on the wood before being cut out. If adjustments are needed, they can be made during this step without throwing off the entire project.
Bandsaw Work and Shaping
Once the layout is complete, the sides of the stool are cut using a bandsaw. Stan recommends staying just inside the marked lines—this way, any imperfections can be smoothed out later with sanding.
After rough shaping, a sanding pass cleans up the edges. At this stage, carpet tape is used to temporarily attach both side pieces together, making it easier to match the profiles during trimming or routing.
Assembly and Joinery
With the pieces cut and sanded, assembly begins. Stan uses wood glue and clamps to secure the main sections, making sure everything is square and properly aligned before letting it set.
Dowels can also be added for reinforcement. Though optional, they add strength and introduce a clean detail to the finished look—something Stan has used in previous projects with success.
Routing and Final Cleanup
To refine the handle and give the stool a finished feel, a router is used to shape the handle cutout. The edges of the stool are also rounded over for safety and comfort, especially if the piece will be used around children or pets.
A thorough sanding pass follows, ensuring all surfaces are smooth and ready for finishing. Whether you choose to stain, oil, or paint the stool, clean preparation here is key to a good final result.
Personal Touches and Custom Options
This build is highly customizable depending on your preferences. You might choose a specific hardwood, add a branded logo, or even carve initials into the top for personalization.
Handles can be made smaller, larger, or skipped entirely based on the final use. The height, width, and foot spacing can also be modified depending on whether the stool is for adults, kids, or workshop use.
Why This Project Is Worth Doing
For new woodworkers, this is an excellent introduction to the fundamentals of layout, tool use, and assembly. For experienced makers, it’s a quick and satisfying build with room for creativity and refinement.
The end result is something you’ll use for years—whether in the kitchen, garage, or around the house. It’s compact, easy to store, and endlessly useful.
Get Stans Plans here: https://www.simplyeasydiy.com/2015/07/diy-step-stool.html.
Matt’s Take
These are my personal thoughts and tips based on my own experience in the shop. This section is not written, reviewed, or endorsed by the original creator of this project.
This is exactly the kind of project that shows how much you can accomplish with basic shop skills and solid execution. Step stools might look simple, but they actually teach several fundamental techniques—accurate layout work, clean bandsaw cuts, and proper glue-ups. The handle cutout is a nice touch that transforms what could be a basic box into something with real character and functionality.
One thing I really appreciate about Stan’s approach is using carpet tape to hold the side pieces together during shaping. It’s a clever trick that ensures both sides match perfectly, and it’s way easier than trying to clamp oddly-shaped pieces. When you’re routing or sanding curved edges, having that temporary bond makes all the difference in getting consistent results.
Safety-wise, rounding over those edges is crucial—especially if kids will be using the stool. Sharp corners on something that gets moved around frequently are just asking for trouble. A simple roundover bit does wonders for both the feel and the safety of the finished piece. And honestly, there’s something satisfying about running your hand along a perfectly smooth, rounded edge that makes the extra step worth it.
The beauty of this build is its versatility. You could easily scale it up for taller people or down for little ones, add non-slip pads to the feet, or even build a matching set in different heights. It’s one of those projects where the basic technique opens up a world of possibilities.