Introduction: DIY Stool Project

By: Junui Lee, Minjoo Lee, Lucy Niu

For this stool you will need:Materials and tools

  • Wood (long planks 1” and 2”)
  • Wood cutting machines
  • Hand drill
  • Drill bits (different sizes)
  • Screw bits
  • Screws (long and medium sizes)
  • Wood glue
  • Sand paper
  • Hand saw
  • Wooden dowels
  • Hammer
  • Foam Paint (spray/regular)
  • Fabric of your choice

Cut List
1” by

  1. 3 Back Panels, 18x3.5
  2. 12 seat slates, 18x1.5
  3. 4 Armrest holders 7x2.5
  4. 1 foot stand 18x5.5

2'' by

  1. 2 bottom bars 25.75x3.5
  2. 4 legs 35x.23
  3. 2 armrests 21.75x3
  4. 2 seat bottom bars 2x20.5
  5. 2 back poles 1.5x15.34
  6. 4 side crossbars 23.75x 1.5
  7. 2 back crossbars 21.875x1.5
  8. 2 underside crossbars 21.375x1.5

Step 1: Step1 : Measuring, Dimensioning, CAD'ing

This is really only a step that is needed if you are planning to create a stool from scratch. If you are looking to create the stool shown in the introduction skip to step two. First, use Autodesk Inventor software to create a design. Dimension each piece so that it is in a ratio of the real-life replica that you would like to create. Then use the software's stress analyzer to check if your design would be viable.

Step 2: Step 2: Gather the Wood and Start Measuring the Dimensions.

Use a Miter Saw or a table saw depending on the type of cut necessary for the wood. Use the Miter saw if the wood needs to be cut at an angle, and use the Table saw for straight and more accurate cuts.

Step 3: Step 3: Start Making the Legs of the Stool

After getting all of the necessary cuts for the wood, it's time to start assembling! Get 4 legs and 2 Back Poles. Assemble the legs and bottom poles in the manners shown in the picture where the legs are parallel with the floor and then attach the bottom bar 2.25 ft above and mark that location. Make sure to use a spirit level to measure that it is even. If it is not even and is leaning towards one side then cut the side as needed to make sure both sides are even. After marking the correct location, place the combination of 2 legs and the bottom pole on a table and use clamps to secure it. then mark 4 spots on the conjunction where the leg and the bars cross, two for each leg.

Step 4: Step 4: Drilling

When drilling, if the screw you are using is too short, a pilot hole must be made first that allows for the head of the screw to fit inside the piece so the screw can extend throughout the juncture. To do this, use a screw bit that is slightly larger than the screw head to drill a hole around 1'' deep. Make sure to be perpendicular to the wood when doing this step. Then use a drill bit the size of the screw tail and mark the distance you want to drill with tape. Then drill to the distance marked. Finally, screw in the screw with an electric screwdriver, regular screwdrivers can work but electric screwdrivers are recommended. Do this for both legs.

Step 5: Alternate Step: Hammering

An Alternate step that worked more effectively was hammering, By simply using 2 nails deep enough to penetrate into both layers and lay secure, we hammered the nails with a hammer for a more secure leg portion. This step may not be applicable to some of the other steps, especially when attempting to hammer at an angle.

Step 6: Step 5: Constructing the Seat

Get the 12 seat Slates and the 2 Bottom Bars and assemble them in a way where there is a 3/8 " dowel worth of space between each of the slates. and place the bars at the ends of the bars as shown in the picture. Then mark each place with a pencil of the 24 junctures. After marking them, use a drill bit to drill an appropriately sized hole and then place a screw to secure the figure similar to the directions of the last step.

Step 7: Step 6: Creating the Backrest

Get the 3 Back panels and the 2 back poles and assemble as shown in the picture. Place the poles flat on the table and place the panels starting from the bottom, 3 inches away from each other so there is space on the top portion. The backrest should be angled for better lumbar support. After assembling these pieces, mark the junctures with a pencil where you would like to drill, so that there is a total of 12 marks, 2 for each juncture. Then drill similarly to the previous steps, and screw in the screws into the holes. Make sure to be perpendicular, and clamp tightly and that the measurements are correct. Precision will be important later in the assembly portion.

Step 8: Step 7: Crossbars

In the cutlist, we listed crossbars for the backrest, legs, and the bottom of the seat. For all of the crossbars, the steps are the same. First align the backrest in the location you desire, then mark the intersection with a pencil. One piece should be above another. Then cut the piece with the line drawn on it so that it is 3 pieces. Throw away the middle piece as it is not necessary. When the remaining two pieces are attached to the other crosspiece, it should form 1 'X' that is level with each other. Mark the intersection with pencil, then drill and screw so that it is secure. Repeat this step for the backrest, legs, and the bottom of the seat. They all have different dimensions so check to make sure they fit before drilling.

Step 9: Step 8: Assembly of the Legs and the Seat

It is time to put the legs and the seat of the stool together. Assemble the 3 pieces in a way where the legs are at the corners of the seats. The dimensions should allow the legs to be positioned almost directly at the corners, perfectly flush with the edges, but if you cut incorrectly, it will not be perfectly flush. However, it is not necessary to be perfectly flush, and the imperfect pieces can still be used, although more measuring and centering is needed so that the center of the legs is at the center of the seat. Make sure to do this step on the floor and use a spirit level (shown above) to make sure it is even and balanced. Mark the desired drilling locations on the corners of the chair and place the seat on the table so that one side is sticking out as shown above. Then clamp the seat that is on the chair to get a secure position to drill. Then use a drill bit to drill one side and screw in the fasteners. After doing so, repeat the process on the other side but this time do it off of the table as there is already a secure reference frame (the other leg). This process will allow for the assembly of both pieces.

Step 10: Step 9: Assembly of Everything

This step is the most complicated portion. You will need to get 2 dowels as shown above. Match the seat with the backrest in the way that you desire, which is usually the backrest bars aligning with the edge of the seat. Then mark the touching portions where you want to drill. Drill approximately half the dowel's length for each hole, and make sure the hole is fairly small as the dowel needs to fit snugly inside the holes. If this isn't secure enough, drill a hole at an angle so that the seat, leg, and backrest are all included in the hole. Then proceed to screw the hole in. Do the same for the other side. The result should be a fairly sturdy singular piece.

Step 11: Step 10: Armrest

The parts of the stool that allow you to sit is now complete. All that is left is the armrest. To make the armrest, get 4 small 1" 3 and place them at the spots which you desire 7" apart. Mark the spots on the chair. Drill the 4 bases into the stool. Then get 2 11x2.5" 1" bars and place them above the 4 bases. Mark the location as where to drill with a pencil then make the holes with the drill bits and screw the screws in. Repeat this step for all 4 holes.

Step 12: Step 11: Additional Reinforcement

If the backrest is still wobbly after all the reinforcement, this is the last step into making it secure. Cut out a 1" piece of wood that encompasses the portion of the backrest to the seat, which essentially blankets both the backrest and the seat. By blanketing both sections and connecting the two sections with a sheet of wood, the balance and security of the juncture becomes much stronger. After creating the blanketing piece, as shown above, mark holes for 4 intersections where the seat and the backrest intersect with the piece, then drill and screw as done previously

Step 13: Step 12: Decorations and Other Aesthetics

Congratulations! You are done with the building section of the stool. For a prettier and comfortable stool, we will first find a cushion that matches perfectly with the backrest. Then envelope it in a cushion with a design of your choice. The outer layer should have laces to tie on that back rungs of your stool, if not create small holes and tie it together with twine or string. Before putting the cushion on, apply the stool with a layer of paint of your choosing. We coated our stool with a layer of black paint. Make sure to apply evenly, and cover all sections of the stool, including the bottom and the insides of the stool. After painting or staining the stool, put in the cushion and Voila! Your stool is finished.