Step 3Material Prep and Assembly
1. Drill out the rivets in the crutches. This will allow you to remove just the adjustable foot portion. If you need a shorter stool this would be the time to cut down the length of the stool leg (my son is pretty tall and I used kids crutches so no cutting for me).
2. Cut seat plywood into circle. I used 12" across but you could adjust based on your comfort. Note: We have two stools in our household one kids and one adult both use a 12" diameter.
3. Router edge to nice profile or file to smooth edge. For that matter you could upholster it I suppose.
4. Finish the wood. I used clear polyurethane but you could also stain or paint it. I also did some light sanding between coats to get a nice durable finish. I used the satin for a furniture grade appearance.
5. Assemble the pipe and flange. Simple just thread them together. I would suggest very tightly. My sons are capable of taking anything apart, so mine are gorilla tight.
6. Pre-drill and assemble pipe to crutch leg and flange to seat. I used self taping screw on all 4 sides. You could also through drill and put a bolt and nut. I thought the tech screw approach would be plenty strong and a clean look. Note: Make sure you offset the holes or the tips of the screws will interfere inside.
7. Adjust to comfortable height and start using.
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