This project was built and designed by Josh Wright. It’s a compact, rustic-style bar stool made entirely from one 8-foot 2×4—showing how much can be done with simple tools and a creative approach.
Josh revisits this popular project years after building the original version, bringing a fresh perspective and updated techniques. The result is a functional piece of furniture with unique character, texture, and a handmade finish.
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Starting with One Board
The entire stool is made from a single salvaged 2×4, chosen specifically for its imperfections. Instead of aiming for a perfect finish, Josh embraces the rustic aesthetic and uses natural defects in the wood to add visual appeal.
He begins by breaking the board down into pieces for the seat and legs. By adjusting the proportions and angles as he goes, he avoids relying on strict measurements and focuses instead on overall balance and appearance.
Making the Seat Panel
The seat is made by cutting short sections of the 2×4 and running them through the bandsaw. Rather than flattening the faces, Josh leaves the bandsaw marks visible, which creates texture and adds to the rustic look.
The pieces are glued together into a panel, and after drying, the entire seat is stained using a homemade steel wool and vinegar mix. This natural stain reacts with the wood, producing a deep black color that enhances grain and character.
Shaping the Round Seat
After staining, Josh rounds the seat using a jigsaw or bandsaw to cut a circular shape. A sanding pass follows to soften the edges while keeping some of the raw marks intact.
The round shape is more inviting and comfortable compared to a traditional square seat. It also creates a stronger visual contrast against the straight, angled legs below.
Cutting the Legs from the Leftover Board
The remaining portion of the 2×4 is cut into halves and then ripped again to form four narrow legs. Rather than sticking to uniform sizing, Josh focuses on shaping each leg to match the handmade feel of the design.
Curves are added to the ends of the legs for a bit of movement and style. These are smoothed out with a spindle sander, though enough tooling marks are left behind to preserve the rough-sawn look.
Joining the Legs to the Seat
To attach the legs, Josh uses a half-lap method where the top of each leg is notched to rest against the bottom of the round seat. The seat’s curved edge means the leg ends must be shaped to fit flush.
A depth stop on the miter saw helps control each cut, keeping the notches uniform. The legs are glued and driven into place, creating a strong connection without using any fasteners at this stage.
Adding a Cross Brace
To improve the stool’s stability, Josh adds a cross brace between the legs. These pieces are cut from leftover offcuts and strategically placed to add strength without taking away from the rustic style.
Instead of using traditional dowels or mortise-and-tenon joinery, Josh experiments with inserting small sections of PVC pipe as tenons. The pipe is cut to size and fitted into holes drilled in each brace, holding the pieces in place.
Staining and Assembly
Before the final glue-up, all the stool components are stained again with the same steel wool and vinegar mix. This keeps the color consistent and allows the bandsaw and sanding marks to show through for a natural, aged look.
Once everything is stained and dried, the stool is assembled. The leg braces are left unglued, allowing some movement in the design, while rusty nails are driven in to secure the cross braces in place—adding both strength and character.
Comparing to the Original
Once the new stool is complete, Josh compares it to the first version he built years ago. While the original served its purpose well, this new version is more refined in shape and better showcases his current woodworking style.
It’s a great reminder of how even small projects can teach valuable lessons and how returning to a design later can lead to new creative results.
One Board, One Project, Big Impact
This project shows how far a single 2×4 can go when paired with a thoughtful design and a willingness to experiment. The rustic aesthetic, simple joinery, and efficient use of material make it a great weekend build for any skill level.
Josh brings personal insight and hands-on technique to every part of the process. From bandsaw textures to reclaimed finishes, the final result is a stool that’s functional, stylish, and full of personality.
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