Need a creative and fun stool for your physics classroom? How about a stool inspired by one of your favorite TV show characters? Follow these steps to create your very own DIY Patrick swivel stool!
Step 1: Cut List
For our stool, we used wood. This was our cut list:
1) 1 thick MDF board (0.75")
2) 1 thin MDF board (0.50")
3) 1 thin plywood board (0.25")
4) 1 2" x 12" board
Step 2: Materials List
Using the cut list, you need to cut out 22 pieces of wood. This was our materials list:
1) 4 x legs - 31.5" x 3.98" x 1.375". Cut these legs with a tilt of 5.436° so that the final vertical height is 28".
2) 2 x short leg supports - 10" x 1.414" x 1.375". Cut leg supports at 45° so that the final shape is a trapezoid.
3) 2 x medium leg supports - 11.25" x 1.414" x 1.375". Cut leg supports at 45° so that the final shape is a trapezoid.
4) 2 x long leg supports - 12.125" x 1.414" x 1.375". Cut leg supports at 45° so that the final shape is a trapezoid.
5) 2 x square MDF baseboards - 20" x 20" x 0.5"
6) 1 x circle MDF baseboard - radius: 9.75", thickness: 0.75"
7) 1 x plywood backboard - 20" x 20" x 0.25"
8) 2 x back supports - 20.332" x 3.484" x 1.375". Cut back supports with a tilt of 5.436° so that the sides are of length 20".
9) 2 x armrests - 17.392" x 2" x 1.375". Cut one end of each armrest with a tilt of 5.436°.
10) 2 x arm supports - 8" x 2" x 1"
11) 2 x triangle supports - 1.5" x 1.5" x 1". Cut along diagonal to create two diagonal supports. Sand down to create curves across diagonal.
12) 1 x rotating plate - 7" x 7"
13) 4 x 1 in. bolts
14) 4 x 1.25 in. bolts
15) 8 x nuts
16) 10 x nails
17) 10 x medium screws
18) 26 x long screws
19) 2 Cushions (18" x 18")
20) Velcro Strips
19) Wood glue
20) Paint (Red, pink, white, black, green, purple, brown - optional)
Step 3: Starting the Project
Now that you have all your materials, you are ready to start. Prepare the seat of the stool by using wood glue to combine the two square MDF boards. Clamp them until dry. Meanwhile, mark the circular MDF board to accommodate 4 legs. Then, trace the rotating plate in the middle of the circular MDF board at the top. Rotate the plate by 45° and mark a hole onto the MDF board. At the mark, draw a circle of radius 0.75". This will be drilled into a hole later so that you can screw in nuts and bolts for the top board as well. Then, trace the rotating plate onto the bottom of the square MDF boards. Shift the square boards from the middle vertically by 1.5", as the center of gravity of the seat will shift when attaching the back supports.
Step 4: The Seat
After gluing the square MDF boards together and tracing the rotating plate onto them, you are now ready to make the seat. Start by using wood glue to combine the back to the back supports. After drying, nail the plywood board onto the sides of the back supports. This will be the back of the seat. Use 5 nails along each length of the plywood board. Then, line up the plywood backboard with the back edge of the square MDF board (along the axis where you shifted 1.5"). Then, use wood glue to combine the back with the MDF board. After drying, drill two holes into each back support and screw in using long screws.
Next, you are ready to attach the arm supports. Start by measuring 3 in. from the opposite side of the MDF board. Then, use the wood glue to attach the arm supports on either side of the MDF board. Make it flush with the edge of the board. After drying, drill two holes from the bottom for each support and secure with a medium screw and a long screw.
Now, you can attach the armrests. place each armrest on the arm supports and push against the back supports. Use a level ruler to make sure that the armrest height is consistent from the back support to the arm support. Also, make sure that both armrests are level in height with each other. Mark the edges of the armrests onto the back supports and glue both armrests onto the back supports and the arm supports. After drying, secure the armrests into the arm supports by drilling and using a long screw. Then, drill each armrest into the back supports from the top at a tilt, and secure with a long screw.
Since the long screws will most likely stick out of the armrests, use a Forstner bit to drill a hole into the bottom of each triangle support. Make the hole deep enough to cover each screw completely. Then, use wood glue to secure the triangle supports over the armrests and back supports.
Step 5: The Base Stool
You can now make the base stool. First, drill the circular hole into the MDF board using a wide Forstner bit. You can optionally add an identical hole at the opposite end as this will help you line up the rotating plate to the seat. Then, use wood glue to attach the four legs onto the circular MDF board. After drying, drill two holes for each leg through the top of the board and secure with long screws.
Next, attach the small leg supports by gluing them on opposite sides to the bottom of the MDF board and the top of the legs. After drying, drill two holes into each support through the top of the board and secure with medium screws. Drill two holes for each support into the legs and secure with medium screws.
Next, line up the medium leg supports vertically on opposite sides of the legs. Glue them both onto opposite sides of the legs. After drying, drill on both sides of each support and secure with long screws.
Next, move down vertically and line up the big leg supports on the opposite sides of the legs. Make sure that these sides of the legs differ from the medium leg supports. The end result should be a square of leg supports that are attached to all sides of the legs. Attach the large leg supports using wood glue. After drying, drill holes on both sides of the supports and secure with long screws.
After screwing in the medium and big leg supports, the long screws will be sticking out at the back of the legs. Grind the ends of these screws off using an angle grinder.
Step 6: Finishing Stool
Now that you have completed the seat and base stool, you can finish building the stool. Start by attaching the rotating plate to the base stool. Drill and secure with 1.25" bolts. Secure with 4 nuts on the bottom of the base stool. Next, drill holes into the bottom of the seat through the holes you traced at the beginning. Next, place the seat onto the rotating plate. Line up the holes with the holes of the rotating plate by using the drilled holes in the base stool to help you have a line of sight. After lining up the 4 holes, screw in the 1" bolts through the top of the seat. From the drilled holes at the bottom, secure the bolts with nuts. Use a wrench through the side to tighten both the nuts.
The final step to building the stool is sanding. Using sandpaper of a hand sander, sand all edges of the stool.
Step 7: Painting
Now that the stool is finished, you are ready to paint. Start by drawing Patrick's face on the back of the seat. Make sure it is large enough to cover the back. Mark his pants at the top of the stool legs and the bottom of the circular MDF board. Mark the bottom of his pants 6" from the ground at the legs. Draw a purple flower on each leg. Paint the top region and bottom of the legs pink with occasional red freckles. This includes baseboards. Paint the pants green and the flowers purple. Finally, paint Parick's face with appropriate colors. After waiting 30 minutes for the paint to dry, add another coat of paint. Finish the stool with varnish. Attach cushions onto the seat using velcro strips. Your DIY Patrick swivel stool is now complete!