This project is by Steve Ramsey from Woodworking for Mere Mortals. This DIY woodworking project is not only budget-friendly but also allows you to create a sturdy and elegant barstool for your workshop or outdoor space.
Step 1: Gather Your Materials
Before starting any woodworking project, it’s essential to gather all necessary materials. For this barstool, you will need:
- Two by three studs (about $2.75 each)
- Handheld power tools
- Pocket screws
- Wood glue (optional)
- Router with a chamfering bit
- Drill with a 90-degree attachment
While selecting your lumber, make sure to sort through the rack to find straight boards with minimal defects. In many cases, the best choice is to avoid the more expensive options like two by fours, especially if they are not kiln-dried.
Step 2: Cut the Boards
Once you have your materials, the next step is cutting the boards to the correct dimensions. The legs and cross pieces for the stool should ultimately be about an inch and a quarter by an inch and a quarter. To ensure accuracy, you can cut two boards at the same time on your table saw.
For the rear legs, they need to be longer since they will also provide back support. After cutting the legs to size, proceed to cut the support pieces, which will include braces for the top, seat, and footrest.
Step 3: Taper the Legs
To enhance comfort, it’s crucial to taper the rear legs slightly. A five-degree angle is sufficient to make a significant difference in comfort level. Use a tapering jig to make these cuts easily and accurately.
If you want to create your own tapering jig, you can find plans available online, which can simplify the process.
Step 4: Create Chamfers
Chamfers are 45-degree bevels cut along the edges of some boards. They serve both functional and aesthetic purposes. Use a router with a chamfering bit to cut chamfers on the ends of the legs, which helps prevent the end grain from splitting when sliding the stool around.
Additionally, applying chamfers to the tops of the back support pieces and the edges of the footrest pieces not only improves the look but also prevents splintering.
Step 5: Assemble Using Pocket Screws
Join the frame using pocket screws. Pocket hole joinery is an effective way to create strong joints. The key is to position the pocket holes where they won’t be visible, such as on the underside of the footrest and the top side of the upper rails.
Before driving in the screws, always clamp the pieces together to prevent sliding out of alignment.
Step 6: Cut the Slats
Next, you will need to cut the slats for both the seat and the back. Ensure that all seat slats are the same width and are spaced evenly. The back slats will be shorter, fitting snugly between the uprights. This uniformity will give the stool a professional appearance.
Step 7: Chamfer the Edges of the Slats
Once the slats are cut, chamfer the top edges of the seat pieces and the front sides of the back pieces. This step not only enhances the look but also helps soften sharp edges, making the stool more comfortable to use.
Step 8: Join the Slats
To attach the slats, cut notches for the upright pieces using a jigsaw. Aim for a snug fit, making adjustments as necessary. Once fitted, glue the slats into place and allow them to dry before clamping.
Consider using dowel pins for additional support, though they will primarily serve a decorative purpose.
Step 9: Sanding
With the assembly complete, it’s time to sand the entire stool. Start with 60 grit sandpaper to remove rough spots, then progress to 120 grit for a smoother finish. Pay special attention to the underside and edges, ensuring there are no sharp corners.
Step 10: Apply Finish
Finally, apply a finish to protect the wood. Steve has been developing his own non-toxic finish that can be applied easily. This step will enhance the beauty of the wood while providing durability for outdoor use.
Conclusion
Building your own barstool can be a rewarding experience. By following these steps and utilizing affordable materials, you can create a functional and stylish addition to your workshop or outdoor area. Thanks to Steve Ramsey for sharing this project, which showcases how woodworking can be accessible and enjoyable for everyone.