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______’s Project

Utility Stool Project

Grade 10 Woodworking

 Create a Bill Of Material (B.O.M.) for the stool project

 Make sure you check each box “AFTER” item is completed

 Always remember to put your name on all your parts

 You can make the subparts in any order. Think of each element as a specific project. Following, each subpart is listed with their specific instructions

LEGS

 Obtain material to fabricate legs from the teacher, check your Bill of Material to ensure you are receiving the correct material

 Using the following steps to fabricate your 4 leg pieces to 1 5/8” x 1 5/8”

  • Rough cut wood to 2” widths on the Green General Band-saw
  • Joint 1 surface and 1 adjoining edge
  • Ensure that jointed surfaces are 90 degrees to each other, if not, they must be corrected. Check with the teacher if you cannot obtain 90 degrees
  • Mark the jointed surfaces with an arrow and a pigtail
  • Arrange your leg blanks so that all arrows are on bottom and pigtails are on the right side of the blanks
  • Set up planer and run all 4 legs through
  • Rotate legs to that arrows are on the left now and pigtails are on the bottom
  • Run legs once more through the planer
  • Adjust planer to remove 1/16” (one full turn)
  • Run legs through the planer again
  • Rotate legs so that arrows are back on the bottom and pigtails are back on the right side
  • Run once more through the planer
  • REPEAT this process until legs are to the correct width and thickness. THEY MUST BE THAT SAME

 Use the following steps to cut your legs to the correct length and angle

  • Set up compound radial miter saw for a compound cut (Blade at 6 degrees to the right of vertical and fence at 6 degrees to the right of horizontal)
  • Bundle all 4 legs side by side to make a large plank. Tape this bundle using just enough tape to hold the planks together (usually once around is enough)
  • Cut 1 end of the plank at this setting
  • Reset saw blade to 6 degree to the left of horizontal
  • Flip plank end to end and cut other end at 27 ¼” in length

 Use the following steps to prepare legs for drilling and to drill the holes in the legs for the spreaders

  • Remove tape and bundle legs together so that the high point of the legs comes together in the middle.
  • Mark each leg at the top with a capital “T”
  • Mark the insides of each face at the dimensions noted on the drawing at the end of these plans. (See video for help with this). Use Link below or scan QR code for video
  • Drill holes for the spreaders into the legs
  • Install a 5/8” diameter Forstner bit into the drill press
  • Ensure drilling jig is set so that the bit is in the middle of the leg and a depth of 7/16” has been set
  • With the top of the leg to the RIGHT, drill all 5/8” diameter holes
  • While jig is still set up, remove the 5/8” bit and install a 1/8” diameter tapered drill bit drill
  • Remove the depth setting
  • Again with the top of the leg to the right, drill holes all the way through the leg in the center of each 5/8” hole.
  • Sand smooth remembering to relieve or round over all edges.

 Tape together, then wrap the legs in paper towels, put your name on them and set it aside in the storage shelves for your class

Crossbars

 Obtain from Mr. Mac 4 pieces of the correct material to be used as crossbars, also known as spreaders

  • If not already done for you, mark the ends of all pieces with an X and cut this X to a depth of 1/16” using a Backsaw
  • Using a ¾” Roughing Gauge, “rough” each piece to create an “ALMOST” perfect cylinder
  • Using the template and a pencil, mark the out to out length and center of each piece

 Using a parting tool and the template as a guide, turn each spreader to the required dimensions

  • 5/8” on each end and 7/8” in the middle

 Using a ¾” Spindle Gauge, turn each spreader to match the diameter set in the middle of each leg

  • After cylinder is complete, use the template and a pencil, mark the “DO NOT CUT” area on each of your spreaders

 While the spreader is turning on the lathe, make lines approximately ½” apart from the do not cut lines to each end of the spreader

  • Again with the Spindle Gauge, taper each end to match the 5/8” diameter you cut earlier

 Using a Vernier Caliper set to exactly 5/8” and a parting tool, re-cut each end to a perfect 5/8”

  • Re-taper the spreaders to this correct end diameter
  • Using Vernier Caliper set to exactly 5/8”, check end diameter of each spreader and adjust as necessary using 80 grit sandpaper

 Finish sand all the crossbars

 Set aside somewhere safe like your locker or backpack

SEAT

 Obtain enough of the correct 1” thick material from the teacher to fabricate your seat

 Crosscut where marked by the teacher to create 14 ½” lengths

 Set the fence on the General Band-saw to 1 ¼”and cut your 1” thick stock. You should end up with approximately 14 pieces that are all 1 ¼” wide

 With the 1 ¼” width standing upright, lay out your pieces to form an interesting pattern

  • You may add other wood to create an even more interesting pattern

 Draw a large triangle on top of all pieces and label from 1 to 14 (or 15 if necessary)

 Joint and plane ALL gluing edges perfectly straight and flush with its matching surface

 Check for perfect jointing between all pieces, re-joint where necessary. Get this checked by teacher

 Obtain 3 large bar clamps and prepare to glue the seat blank

  • Set clamps to correct opening so that all your pieces will fit
  • Put one clamp on the floor (this will be used shortly)
  • Lay paper-towel on the desk under the clamps to collect glue drippings
  • Glue all pieces together
  • With the clamps set as far apart as possible, tightly clamp the two bar clamps ensuring the underside of all the pieces are aligned flat
  • Wipe off all excess glue
  • Add the third clamp to the top and tighten
  • Flip the blank over and wipe off remaining excess glue
  • Clean up all your paper towels

 Next class, remove the clamps, clean them and then put them away

 Plane the blank to 1” thickness

 On the underside of your balnk, determine center and drill a ¼” diameter hole to a depth of approximately 1/4”

 Set up the circle cutting jig on the Grey Delta Band-saw

  • Using this jig, cut the seat to a diameter of 13”

 Using the stationary disk sander, rough sand all the edges to remove the band-saw marks

 Using a rasp, rough out a rounded edge on the top of your seat

 Using a smoothing file, smooth over the rounded edge

 With a Random Orbit Sander, fully sand your seat starting with 80 grit, then 150, finishing with 220.

 With a ¼ sheet (square) sander, polish the edges of your seat

  • If you still see any un-sanded areas, go back to the 80 grit and fix as required

 Get the seat checked over by the teacher

 Wrap the seat in paper towels, put your name on it and set it aside in the storage shelves for your class

UPPER SEAT SUPPORT

 Obtain correct material from the teacher.

 Rough cut this stock to approximately 7” x 12”, if not already at that size

 Using the planer, plane this board to exactly 5/8” thick, remember to keep flipping the board over so that both sides are planed

 Joint one edge

 Put your name on it and set it aside with your seat

LOWER SEAT SUPPORT

 Obtain correct material from the teacher

 rough cut this stock to 12” x 6”

 Using the milling wood steps, make this board exactly ¾” x 5” x 5”

 Do not throw out the offcut, you can use this if something happens to your original piece

 Install “Riving Knife” into a table-saw

 Set blade height to 1 ¾”

 Perform all table-saw pre-checks

 Using the lower seat support jig, create corner notches in the lower seat support

 Completely sand everywhere except the notches

 Put your name on it and set it aside with your seat

ASSEMBLY

 You can now cut the ends of your spreaders on the grey Delta band-saw and “gently” grind off the burrs with the 1” belt sander

 Obtain:

  • a role of clear packing tape
  • the assembly block
  • your legs
  • your lower seat support

 Arrange legs into correct orientation

 Place the lower seat support and the block into the legs

 Tape the top of the legs tightly together

 Tape the lower seat support into position so it can’s fall out

 Install the spreaders

 Wrap tape above the legs to hold the seat base together

 While stool is assembled, using 3/8” deep countersink drill bit, drill through small holes in leg until you have created a deep countersink in all locations (8 holes need to be drilled)

 Using #8 x 2” long deck screws, carefully screw legs into crossbars using cordless drill (SET CLUTCH TO #10 and tighten until the clutch “quacks like a duck”)

 With a #2 Robertson Screwdriver, finish tightening all the screws

 Using the upper seat support material you prepped earlier, follow the video below to make the support to the correct size

  • (See video for help with this). Use Link below or scan QR code for video

 To drill and install the upper seat support, follow the video below

 Remove all the tape and lower seat support

 Sand the top of the legs to match the upper seat support, starting with 80 grit

 Using a 3/8” tapered plug cutter, make up twelve plugs from a piece of scrap wood of your choice.

 Test fit plugs into seat holes, small end goes into hole

 If the plugs are correct, using glue and a mallet, install plugs into holes over screws in the legs

 Completely wipe off all excess glue

INSTALLING THE SEAT

The following video can also be used as reference for installing your seat

 Obtain the following:

  • 8 – 1 ¼” deck screws
  • 1 ¼” shallow countersink drill bit
  • ¼” assembly dowel
  • ¼” drill bit

 place seat upside down on a sanding mat

 place dowel into ¼” hole in seat

 drill ¼” hole into middle of the upper seat support

 turn base upside down and place onto dowel

 pre-drill countersunk holes into seat using holes in upper seat support as a guide

 Install 4 - 1 ¼” deck screws

 Mark lower seat support for drilling as per drawings at the end of the plans

 Install lower seat support, tap in with mallet if necessary

 Countersink drill holes through lower seat support

 Attach with 4 - 1 ¼” deck screws

 Once seat is installed, use flush cut saw to carefully cut plugs

  • Lay seat onto its side
  • Lean against the seat to stabilize and,
  • Carefully cut plugs using a flush cut saw

 Once plugs are all cut off, using a random orbit sander, sand all the plugs flush using all three grits. You should not be able to feel the plugs at all after sanding

 Last chance for any final sanding.

 Remove seat, and prepare for oiling, you will need the following

  • Danish Oil container
  • Danish Oil can
  • Gloves
  • Paper towel
  • Flame tamer for disposal

 Apply oil, let sit for 20 minutes, then wipe off completely a minimum of three times (DO NOT apply oil three times)

 Re-attach seat

 Tag with you name

 Complete Self-evaluation

 Hand in for marking

 Stool is complete, YEAH!!!!!