Procedures for making the stepping stool.

Obtain the wood (¾” thick) necessary to construct the stepping stool.

Top Piece

  1. Be aware of defects in the wood that you want to cut around or include in your project.
  2. Cut a 14” longpiece using the miter saw.
  3. Square one edge.
  4. Measure from this square edge 14” then mark along the edge of the board.
  5. Make a square cut on waste side of the line.
  6. Use the router to round over the top edge.
  7. Choose the bit you of your choice.
  8. Adjust the bit to the proper height.
  9. Sand the entire board with a block (80 grit along the grain of the wood) then with an orbital sander (80 grit).
  10. Sand with an orbital sander (100 grit). Round corners slightly.
  11. Sand with just your hand (120 grit along the grain of the wood).

Leg Pieces (2 count)

  1. Cut a 7” wideboard with a 5° bevelusing the miter saw.
  2. Use the miter saw to square one end with a 5° bevel.
  3. Measure 7” from the square beveled edge then mark along the edge of the board.
  4. Cut on the waste side of the line using a 5° bevel.
  5. On one of the beveled edges measure in ½” and place a mark. On the same edge but from the other side measure in ½” and place a mark.
  6. Draw a line from this mark to the corner on the other end of the board. Do the same for the other side.
  7. Use a band saw to cut along this line. Removing the shaded section. Your piece of wood will be 7” on one side and 6” on the other side when you are finished.
  8. Use a hand plane to smooth out the band saw cut marks if needed.
  1. Mark 1” in from each side on the 7” side.
  2. Use a round bucket to mark the arch cutout.
  1. Use the band sawor scroll saw to cut the arch out. Cut slowly and accurately.
  2. Use the Osculating Spindle Sander to sand the inside of the arch. Attach the largest sanding drum.
  3. Sand the entire board with a block (80 grit along the grain of the wood) then with an orbital sander (80 grit).
  4. Sand with an orbital sander (100 grit). Round corners slightly.
  5. Sand with just your hand (120 grit along the grain of the wood).

Support Piece

  1. Cut a 3” wide board 8” long using the miter saw so that you have a 5° angle on both sides to make a trapezoid.
  1. Using the miter saw, cut one edge at the 5°angle.
  2. Measure 8” from thepointed corner and cut the other side with the same 5° angle to make a trapezoid. One length of the board should be 8” and the other 7 ½”.

  1. Mark ½” in from each end on the bottom (8” edge).
  2. Use a bucket to mark an arch.
  1. Cut the arch out with a band saw or scroll saw.
  2. Use the Osculating Spindle Sander to sand the inside of the arch.
  3. Sand the entire board with a block (80 grit along the grain of the wood) then with an orbital sander (80 grit).
  4. Sand with an orbital sander (100 grit). Round corners slightly.
  5. Sand with just your hand (120 grit along the grain of the wood).

Staining

  1. Clean the sawdust off all pieces with the air compressor.
  2. Tack cloth each piece. This removes dust that is still on the wood
  3. Lay your pieces on newspaper
  4. Stain with your choice of stains using the foam brushes after mixing the stain.
  5. Wipe your extra stain off with paper towels.
  6. Be sure all lids are placed back on the stain cans securely
  7. Let dry overnight.

Assemble the Pieces

  1. Mark the center of the leg piece alone the top edge.
  2. Use a square to draw a straight line down from the top of this piece along the inside of the piece. Check you bevel to know the inside and outside of you pieces.
  3. Mark 3/4” and 1 3/4” from the top for the screw placement.
  4. Drill a pilot hole in these locations with a 1/8” drill.
  5. Use a counter sinker bit on the outside to allow the head of the screw to be flush with the wood surface.
  6. With one leg piece upside down, position the center support piece in place (upside down as well).
  7. Use the same pilot drill bit to drill through the existing hole of the leg, now drilling into the center support pieces. Do this for both sides.
  8. Place a layer of glue on the edge of the center piece that comes into contact with the legs.
  9. Insert a 2” wood screw into each of the2pilot holes.
  10. Align the center support piece to the center of the leg piece and begin screwing until tight.
  11. Attach the other leg piece to the opposite side of the center support piece by repeating steps6-10.
  12. Turn the project right side up.
  13. Place the stepping stool top piece in position on the assembled bottom legs and support pieces by making sure the underside measurements are even from side to side.
  14. Make a mark on the top of the stepping stool that is 2” in from the outside edge of the top. Do this for each leg. There will be 4 marks all together.
  15. Drill a 1/16” pilot hole at each mark. Be sure to drill at a 5° angle.
  16. Place a small amount of glue on the top of the legs and center support piece.
  17. Realign the top to the bottom.
  18. Use four number 4 finish nails to attach the top to the sides.
  19. Use a nail punch to sink the nail head a little bit into the wood.
  20. Allow your project to dry.

Polyurethane your project

  1. Tack cloth your assembled project.
  2. Use the styrofoam brush and apply a light, but even coat of polyurethane and let dry overnight.
  3. Use a fine steel wool pad to sand the project.
  4. Blow the project off with compressed air
  5. Tack cloth the project
  6. Use the styrofoam brush and apply another thin coat of polyurethane. Thick coats will cause drips to form in the polyurethane.
  7. Let dry overnight.