Build a Step Stool in an Hour
Introduction: Build a Step Stool in an Hour
I built the painted step stool shown back around 2008 at the Toronto Woodshow. It was a beginner project that kids who visited the show could build right there at the show.
I was one of the staff who would take a child through a workshop guiding them (one on one) through the building of one of these simple step stools. At the end of the weekend I had built a few extra for myself which I took home for my own kids -- hence the bright and colourful paint job on this one!
I have simplified the build process so you can build this with just three common power tools: a Drill, a Jigsaw, and a Miter saw. I think it is a very beginner-friendly project. It teaches several basic woodworking skills, and at the end you have a useful compact step stool.
And you should be able to build this in less than an hour.
All you need is a short length of 1x3 and 1x8 pine from your local building supply store.
For absolute beginners: In North America these types of boards are readily available at most large building-supply stores. A 1x8 board is 3/4" thick and 7-1/4" wide. A 1x3 board is 3/4" thick and 2-1/2" wide. (the 1x8 refers to the rough dimensions before the wood is planed smooth, but I agree that this terminology can be confusing to beginners!)
Here are all the major dimensions: The Top and legs are both cut from some 1x8. The Top is 12" long, and the legs are 6" long so you only need roughly 2ft of 1x8.
So the Top is 12 x 7-1/4 x 3/4, and the Legs start out 6 x 7-1/4 x 3/4. The Center support is a 10" piece of 1x3 -- so 10" x 2-1/2" x 3/4".
For my metric using friends, the dimensions are: Top 305mm x 185mm x 20mm. Legs 152mm x 185mm x 20mm. Centre Support 250mm x 65mm x 20mm
Step 1: Option: Video Build
If you prefer, a detailed video of the build is available
Step 2: Straight Cuts First
Start at the miter saw and crosscut the top to 12" in length, and the two legs to 6" in length, and finally cut the centre support to 10" in length.
My saw cannot cut the full width of the 1x8 so I need to flip it over after the cut and cut a second time to finish the cut.
Step 3: Curved and Angled Cuts
There is a semi-circular cutout at the bottom of each leg. 431
First draw a line down the center of the board. We will also need this later on to guide where to drill when assembling the project, so draw it the full height of the leg.
Then set a compass to 2", and draw a semi-circle centred at the bottom of each leg. I find it easier to mark out for the semi-circular cutout while the legs are still rectangles, which is why we do this step before going back to the miter saw to cut the angles on the legs.
Now Back to the miter saw.
Each leg is angled inward at about 7-degrees. Set the miter saw to 7 degrees and cut this angle onto each leg. There is no need to measure or mark lines, just position the leg so that the cut starts at the outside corner of the 1x8 leg piece and make the cut.
Clamp the leg to a bench and use a jigsaw to carefully cut out the semi-circle from the bottom of each leg. You may need to stop part-way to reposition the jigsaw (I did) if the clamp blocks the jigsaw from cutting the entire semi-circle at once.
Step 4: Sanding, Marking, Drilling
The pieces are all cut out, so you are almost ready for assembly. First take some time to sand the pieces smooth. If you have a power sander, you can use it. However, pine is quite soft, so you can also hand-sand it very quickly using 150 grit sandpaper. How far you take this step depends on how you plan to finish the step stool. If you are going paint it, then 150 grit is plenty smooth.
Lay the centre support on the leg and use it to gauge where to make a few cross-marks on the centre line, so you know where you will drill two holes for screws. The two legs will each have two screws attaching it to the centre support.
Use a countersink bit in your drill to drill pilot holes into the legs. 56