This design was created by Josh Wright from Josh Wright Woodworking, and it’s perfect for any home or outdoor space. In this guide, you’ll learn how to make a sturdy bar stool using just one 2×4, making it an affordable and beginner-friendly woodworking project.
Materials and Tools Needed:
- 1 – 2×4 (8 feet long)
- Wood Glue
- Polyurethane for finishing
- Miter Saw
- Table Saw
- Jigsaw
- Orbital Sander
- Low Angle Jack Plane
- Card Scraper
Step 1: Cut the Legs
Start by setting your miter saw to a 5-degree angle. Cut two pieces of the 2×4 to 23 inches for the legs. Make sure to flip the board for each cut to keep the bevels parallel.
Step 2: Prepare the Legs
Using the table saw, cut off the round edges of each leg and rip them down the middle to create four legs.
Step 3: Create Dados for the Center Brace
Set your table saw blade to 5 degrees and ¾ inch high to cut a dado on each leg, about 7 inches up. This will hold a center brace that you’ll make later. If you prefer, you can simply screw the center brace onto the legs.
Step 4: Make the Cross Brace
Cut a piece of the 2×4 to 2¼ inches for the cross brace, also at a 5-degree angle. This time, the cuts should not be parallel. Then, cut off the round edges and rip the piece down the middle.
Step 5: Cut Half Laps for the Cross Brace
Mark out and cut half laps in each piece to make the cross brace sturdy.
Step 6: Create the Seat
With about 37 inches of the 2×4 left, cut three 12-inch pieces for the seat. Again, no bevel is needed for this part.
Step 7: Prepare the Seat Pieces
Rip the three pieces into nine 1-inch strips, only needing eight for a 12×12 seat. Use the extra piece if you want a wider seat.
Step 8: Assemble the Seat
Once the glue has dried, use a low angle jack plane and card scraper to clean off the glue and flatten the surface. Then cut everything square with the miter saw.
Step 9: Shape the Seat
If you prefer a round seat, use a jigsaw to cut it out and clean it up with the orbital sander.
Step 10: Chisel Slots for the Legs
Chisel out shallow slots on the seat to hold the legs securely.
Step 11: Assemble the Stool
Now that all pieces are ready, glue everything together to form the bar stool.
Step 12: Sand and Finish
Sand everything flush up to 220 grit and give the seat a slight round over for comfort. Finish with polyurethane to protect your work.
Now you have a beautiful, sturdy bar stool made from just a single 2×4!
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