This project was built and designed by Josh Wright. It’s a thoughtfully constructed bar stool built from reclaimed pallet wood, combining sustainability with strong joinery and a comfortable design.
Josh walks through each step of the process, from rough wood prep to decorative details like inlaid dovetails. The result is a one-of-a-kind piece that balances rustic materials with refined woodworking techniques.
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Starting with the Seat
The build begins with constructing the seat using two pieces of pallet wood. These boards are cut to identical dimensions and glued together to form a strong base.
To improve comfort, the top is shaped into a slight curve. Josh removes material using an unconventional—but effective—technique with a radial arm saw and table saw, followed by chisels and sanders for fine-tuning.
Making the Legs
Once the seat is shaped, attention turns to the legs. These are also made from pallet wood and cut with a five-degree angle to provide both stability and an inward lean that improves the stool’s visual balance.
Each leg is sized and shaped to match the overall proportions of the seat. Consistency between all four legs is key for proper balance and strength once assembled.
Adding Leg Supports with Inlaid Dovetails
To connect the legs and add lateral support, cross-braces are added using a five-degree angle cut to match the leg orientation. These braces are fitted using inlaid dovetail joints—an advanced technique that adds both strength and a decorative feature.
Josh uses hickory for the inlays, offering a sharp contrast against the darker reclaimed wood. Each dovetail is outlined, cut, and carefully cleaned up before gluing into place.
Cutting the Dovetails and Inlays
Rather than calculating the angles mathematically, Josh traces the dovetail shapes directly and uses a pull saw and chisels to shape the mating parts. This approach reduces guesswork and allows for precise fitting by eye.
Once glued and dried, the inlays are trimmed flush with the surrounding wood, leaving behind a clean, geometric detail that elevates the overall design.
Mortise and Tenon for the Seat Connection
To secure the legs to the seat, Josh uses a traditional mortise and tenon joint with a twist. The tops of the legs are cut at a five-degree angle to match the lean, ensuring a flat connection with the underside of the seat.
Mortises are marked and cut into the seat using a jigsaw. Each leg features a slot for inserting wedges, turning this into a wedged mortise and tenon joint for added strength and resistance to movement over time.
Assembly and Adjustments
As with many hand-fit joints, a few adjustments are needed during assembly. Some of the wedge slots are too tight and require cleanup with a chisel to allow proper insertion.
Wedges are cut from leftover inlay material, providing both a functional and visual link to the dovetail accents. They are tapped into place with glue, locking the legs securely into the seat.
Final Touches and Sanding
After assembly, the stool is given a full sanding to remove any rough surfaces. A card scraper is used to reach tight areas and clean up any lingering glue or saw marks.
The seat edges are chamfered to soften transitions and improve comfort. These small details make a big difference in the final feel of the stool.
Applying Finish
Josh finishes the stool with several coats of polyurethane. This helps protect the wood from wear and enhances the natural character of the reclaimed materials.
The polyurethane also brings out the contrast between the oak pallet wood and the hickory inlays, tying the whole project together visually.
Why Reclaimed Projects Matter
This project highlights the beauty and value of using reclaimed wood. Pallet boards that might otherwise be discarded are transformed into something functional, stylish, and long-lasting.
It also encourages woodworkers to think creatively with materials and emphasizes the importance of working with what you have. The imperfections of reclaimed wood add character, while the process offers plenty of room for experimentation and learning.
A Great Skill-Builder
Techniques like inlaid dovetails and mortise and tenon joinery are foundational woodworking skills. Practicing them on a project like this offers a hands-on way to grow your abilities while producing something useful.
For those just getting started in woodworking—or looking to challenge themselves with more advanced joinery—this stool project offers a great mix of practicality and craftsmanship.
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