Typically bar stools come with thin legs, but I decided to make this DIY wooden Bar Stool with legs from trimmed 4x4 lumber. This bar stool looks bulky, but it’s a perfect fit for my mother-in-law’s dining table that I made several months ago.
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• 4x4x8' (x1)
• 2x6x8' (x1)
Tools for this project
• Kreg Jig
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Step 1: Step-1 Cut 4x4 Boards for the Legs
Take 4x4 board and cut into four pieces to 22 1/2" in length. These will be the legs for the bar stool.
Step 2: Step-2 Make a 5° Cut on One Side of Each Leg
Next, measure and mark 2" from the top of the leg. Then from the 2" mark cut the 4x4 board at 5° angle all the way down using a Table Saw. I made a jig out of 2x6 to help me make this 5° cut. See photo. Make this 5° cut on all 4x4 pieces.
Step 3: Step-3 Make a Second 5° Cut on One Side of Each Leg
Rotate the 4x4 board 90° and again, from the 2" mark, make a 5° cut all the way down. Now you should have two sides with a 5° cuts and the other two untouched.
Step 4: Step-4 Cut Upper Let to 5°
Next, cut the upper 2" section of the leg to 5° as shown on the picture. Again you’ll have two sides of the leg cut and two sides straight/untouched.
Step 5: Step-5 Make a Bevel Cut on Upper and Lower Section of the Leg
Make a jig from 2x6 piece of by cutting 45° grove in the middle. Then take the straight side of the leg and place it inside the grove. On the upper section of the leg, measure and mark 1 1/2" from the center of the ridge. Then set your Miter Saw to 5° bevel and make a cut. Next, measure 21" from the top of the straight side of the leg and make a 5° bevel cut as shown on the picture.
Step 6: Step-6 Cut 2x6 Boards for the Seat
Take 2x6 and cut three pieces to 14" in length. Rip off 1/4" on both sides of the middle section, and on the inside of both edge sections, see picture. For the area where legs go, cut out 3 1/4" x 3 1/4" squares on four sides. Then drill pocket holes as shown on the picture for 2 1/2" Pocket Hole Screws. Apply Wood Glue in all the seams, then clamp and screw boards together