Introduction: Japanese Barstool With Tusk and Tenon Joint
This is my very first piece of furniture built using strictly joinery. I use a #Tusk #Tenon #Joint as well as some more traditional joinery to create this Japanese inspired chair / stool, also known as a contemplation stool. I am starting to fall in love with woodworking so I decided I wanted to create a chair strictly using wood. I used walnut and white oak. This chair will be entered into the builders challenge instagram woodworking contest.
Step 1: Watch the Full in Depth Build!
Full video of this build with all the commentary, details and instructions.
Step 2: Mill Lumber and Cut Down to Size
I am using 6 Quarter Walnut and some thin white oak for this entire build. I start off by milling up the walnut by cutting it down to size on the miter saw, using my #6 hand plane to get one side perfectly flat then ripping it down the table saw to get the other side perfectly flat. For both stool legs I put them through the thickness planer to get them perfectly flat. For the actual seat I used an already bowed piece of walnut and did not put it through the planer because I wanted to keep the bow for the natural curved look of the Japanese style stool.
Step 3: Glue Up & Secondary Inlay.
I did the first glue up by sandwiching some 1/4" white oak between the walnut in both legs and the seat. Once dried I used my miter gauge on the table saw to rip all three pieces again, so I can glue up once more some white oak down the side of each piece.
Step 4: Tapering Jig / Curving Each Piece and Rough Sanding
I used a tapering jig to taper both legs slightly at about 1/2" on either side. I think this will give it a good contrast from the wide seat. I then needed to create the curve in each piece. Both legs, and the seat will have a slight curve so I took it to the bandsaw and cut out the curve. I then used some 60 grit sandpaper to clean up all of the bandsaw marks.
Step 5: Epoxy Knot and Taper Seat
I used some black epoxy to fill in a knot that was loose on one of the legs. I then put a 70 degree bevel on the seat. This deemed a bit tricky because it was curved. I had to put a large shim under opposing side to keep the cut flat and 70 degrees.
Step 6: Shouldered Tenons on the Legs.
I created shouldered leg tenons by ripping a 1/2" cut, then finishing it off by taking it to the bandsaw. I then had to cut the shoulders by using my pull saw. I cleaned everything up with a chisel and sandpaper.
Step 7: Seat Mortise
To create the seat mortise I first bored out material with a forstner bit on the drill press, then cleaned everything up using a chisel. I then did a dry fit and luckily they fit perfectly!
Step 8: Stretcher
For the stretcher I sandwiched white oak between walnut and cut out a curve using the bandsaw. To match the seat top I also beveled both ends at 70 degrees.
Step 9: Shouldered Stretcher Tenon
I created the shouldered tenon on the end of the stretcher by making multiple cuts using my miter gauge on the table saw. To cut the curved section of this I had to bring it over to the bandsaw. I then cleaned everything up with the chisel and sandpaper. I then did a dry fit and everything fit as it should!
Step 10: Mortise in the Legs
I created a Mortise in each leg by first boring material out using the drill press with forster bit. I then used the chisel and hand files to clean it up and get a perfect fit.
Step 11: Tusks
For the Tusks I used an opposing white oak with walnut inlay. I drew out my tusk design then cut it out on the bandsaw and then finished by sanding to 220 grit.
Step 12: Stretcher Mortise
I bored out material using a forster bit on my drill press then cleaned everything up with a chisel and hand files.
Step 13: Dry Fit/ Final Sanding/ Glue Up / Finish
I did a dry fit to make sure everything fit together snugly. I then did a final sanding of every piece up to 220 grit before gluing up. I decided to use 5 minute epoxy for this glue up just to add some more strength than conventional wood glue. Once everything was dry I did some touch up sanding and finished everything using Festool's heavy duty finish.
Step 14: Watch the Entire Build!
Thank you for viewing this instructable. It was a lot of fun to build and I plan on doing some more woodworking soon!