How to Make a DIY Bar Stool

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About: I love to build DIY wood projects.

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.

Visit our website for more info and pictures TheDIYPlan

Supplies:

• 4x4x8' (x1)

• 2x6x8' (x1)

Wood Glue

2 1/2" Pocket Hole Screws

Tools for this project

Drill

Tape Measure

Sander

Pivoting Bit

Table Saw

Kreg Jig

Miter Saw

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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

Step 7: Step-7 Attach the Legs to the Seat

Now attach the legs with 2 1/2" Pocket Hole Screws and Wood Glue. You will need to use pivoting bit tip holder to get those screws in because of space constraint.

Step 8: Step-8 Install Leg Support

From the remaining piece of 2x6, cut 1 1/2 x 1 1/2" strips of wood. Then measure the distance from leg to leg at the seat and cut to that exact measurement at 9° on each end. Drill pocket holes on the back side. Use Wood Glue and 2 1/2" Pocket Hole Screws to attach these boards.

Step 9: Step-9 Install Footrest

Similar to step 8, measure and cut 1 1/2 x 1 1/2" footrest at 9° on both ends. Two of the footrest will be higher than the other two, so measure accordingly before making the cut. Drill pocket holes on the bottom of each footrest and attach them using 2 1/2" Pocket Hole Screws and Wood Glue.

Step 10: Step-10 Sand and Stain

Last step is to sand the bar stool 220 grit paper, then apply Pre-stain before staining. Once the stain dries, apply Polyurethane. You're done with DIY wooden bar stool.

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