Artist Stool Made From Reclaimed Materials.
Introduction: Artist Stool Made From Reclaimed Materials.
I made this stool from reclaimed materials as part of an Industrial Design Project at the University of Johannesburg. The importance of the stool as a piece of furniture in the studio or workshop needs to be a form that inspires or stimulates creativity and design. The objects around us while we create have an impact on the work we produce.
WARNING
This project uses dangerous tools and materials, only do what you are comfortable with and under correct supervision. Woodwork and metalwork are dangerous, wear a thick leather apron, Gloves ( When suitable), Hearing protection, a face shield AND eye protection. The aluminium casting releases many toxic fumes and may often spray molten aluminium unpredictably as the gas escapes from the mould. Make sure to wear full PPE and only 100% cotton clothing and thick closed boots.
This project used a wide variety of materials and tools to create. There are many alternatives available this is just what I had access to and am comfortable using.
Materials:
1. Seat and legs
2. Oregon Pine floorboards (Old pallets could also work well)
3. Old woollen jersey for cushion Variety of foams (yoga mats, electronic packaging and upholstery foam all work well)
4. Second-hand cork samples for padded feet
Joint
1. Used Aluminium Cans and broken Window frames
2. Rebar or other metal rods
3. 3D printing filament
4. Lots and lots of small nuts and bolts
5. A small Tub of vaseline
6. Beeswax ( Can be remelted and reused afterwards)
7. Plaster of Paris, <PERSON> and water for the lost wax mould
Other materials
1. 500ml cold glue
2. 2 part epoxy ( Longer cure time means a stronger joint)
3. Very long wood dowels and shorter ribbed dowels for joining the strips of wood together
4. Sandpaper ( 110, 220, 400 and 600 grit )
Tools and equipment
Seat and legs
1. Table saw
2. Band saw
3. Oscillating drum sander
4. Jig Saw
5. Palm Sander
6. Belt sander
7. As many clamps as you can buy, and then some
8. Craft knife
9. 787
Ruler
10. Measuring tape
11. Superglue
12. Masking tape
13. Vernier
14. Drill press
15. Long 8mm drill bits
16. Hammer
17. Nails
Cushion
1. Seam ripper
2. Crochet hook
3. Scissors
4. Patience
5. Time
6. More patience
Joint moulding
1. 3D printer ( Local Makerspace)
2. Stove
3. Pot of boiling water
4. Small oven to melt out beeswax ( Apparently you can use a regular cooking oven but I wouldn't risk it )
5. Sand
6. Buckets
Joint Casting
1. Homemade foundry ( I will eventually make another instructable)
2. Crucible
3. Homemade casting tools ( Long spoons, tongs etc)
Step 1: Photos of the Stool
Step 2: Detail Photos
Step 3: Technical Drawings
Here are a series of technical drawings I created from 3D models that I made in Solidworks.
Step 4: Sourcing Materials
Step1: Sourcing materials
This project was made from reclaimed materials and as such they must be found. Building sites are fantastic sources for old wood and Aluminium. Window frames are regularly thrown away when damaged and are easy to find, bring a magnet (Al is non-magnetic) to make sure you are not picking up another material. Reclaimed wood often has nails or staples in it so be very careful when cutting and working with it. Second-hand stores often sell cheap or free jerseys with holes in them which are perfect for the cushion, alternatively check in your closet and you might be in luck.
Step 5: Aluminium Joint 3D Mould
The joint was first modelled in SolidWorks (3D modelling software) and using various features ( Shell, extrude and mould) I created a three-part mould. I made it so that each part is identical so it is much easier to 3D print. Using a 3D printer at my university I was able to print the parts in three different colours of PLA.
Spray a clear coat on each mould part and add a THICK layer of Vaseline to all of the parts.
Attach the mould together using nuts and bolts and then melt beeswax in a pot of boiling water and pour into the mould when liquid. 220