Monday, October 2, 2017

Ana White's Simplest Stool Build

Every morning I like to get up early and sit in my garage with a cup of coffee and the garage door open and enjoy the beauty of where I live.

But as far as seating goes in my garage, all I have is one of my 2 'poppy benches' which I use for a lot of my projects - and it shows!  It's a rather dirty looking thing.

So I decided to make a small stool for me to sit on in the mornings.  This stool is from Ana White's plan catalogue, which you can see by clicking here.

To make this stool I'm going to recycle some materials from a few builds that I recently dismantled.  I have a few 2x4s...

a few 1x12s of various size...

and some 1x2s.

I printed out Ana White's plans...

...and began by cutting the 2x4s to size.

I day prior to this project I built this outfeed cart for my table saw.

Essentially it's my old table saw top attached to 2 legs with 45 degree-cut supports.

These angled supports help keep the top close to my table saw top while not touching the motor or belt.

But back to this project - when cutting the legs I first made a cut half way through the wood, then flipped it over to cut the remaining material.  This is a good way to cut thicker material, however, since the wood I was using wasn't perfectly square, the cut wasn't even.

So I ran the wood through the surface planer to make sure the tops and bottoms were flat.

Then I recut all the wood.  I now have the 4 legs.

The legs will all be cut on an angle, so I set my miter saw to cut at 5 degrees, with a 5 degree bevel.  I used a stop block to make sure all the legs were cut the same.

When all the cuts were made to the legs, I cut the other side of each leg with the same 5 degree miter and bevel.  This makes sure that the legs will sit flat on the floor even when at an angle.

As Ana White suggest, I marked the inside corner of each leg.

With the legs done for now, I worked on marking all the 1x2s for cutting.

All of these will also have a 5 degree miter (but not bevel).

Once I cut one side, I changed my miter saw to cut minus 5 degrees on the other side.

With all those pieces cut, it was time to begin assembling everything.

I used small pieces of 1/4" plywood to raise up the height of the 1x2s and attached them with spad screws.

Once one pair of legs were done I repeated the process for the other pair.

Then I connected the 2 pairs with more screws.

I used a clamp to help make sure everything stay aligned correctly during assembly.

And after about 30 minutes the legs and supports were done.

Then I used one of the pieces of 1x12 for the seat.  This was simply screwed onto the frame.

With the stool all done, I spray painted it with some light blue spray paint.

At this point you may have realized that I have not sanded this thing at all, and you are correct.  I plan on doing that once all the paint has dried.

When the top was done, I flipped over the stool and painted the bottom.

After letting the paint dry all day I then, finally, began sanding.

I first sanded with 60 grit sandpaper, and then finished with 220 grit.

After wiping it clean with a damp cloth, I'm done!

It's definitely rough-looking, but it does have a certain charm to it.

My wife loved it when she saw it.

 So I decided to build another one.

 I still had enough 2x4s for the legs...

For the 1x2s I simply cut some of the remaining 2x4s into strips .75" thick.

I followed the same steps as the first stool and before long I had a second stool.  This one I painted an olive green color.

Once the paint dried I sanded it, cleaned it off and now I have a second stool!

This was a fun little project that only took a couple of hours to do (for each stool).

Ana White's plans are easy to understand and follow.  Thanks Ana!

Now my wife and I have nice stools to sit on while watching those sunrises.

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