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Pocket screws function clamps for panel glue-up.

Inspired by a typical Shaker step stool, this model employs pocket screws to hitch each the aspect panels and the helps. To lower down on the variety of rip cuts, I used three items of 1×6 dimensional lumber to kind the aspect panels (1×6 truly measures 34” x 512“), so this model additionally finally ends up a bit deeper than a conventional Shaker stool – and thus a little bit sturdier and beefier wanting.

First, use your miter noticed to chop the 1×6 items to size for the aspect panels. You’ll want two every at 2014“, 1314” and 614“.

Now, clamp one of many 2014” items flat to your bench (face aspect down), and drill holes for 2 pocket screws alongside the sting that can meet the center piece. Place one gap 2″ from the underside edge, the opposite at 11″. Repeat with the second 2014” piece. Now drill every 1314” piece alongside the perimeters that can meet the brief items. Locate one gap 3″ from the underside edge, the opposite at 514“.

Next, it’s time to connect up the aspect panels, and that is the place the pocket screws turn out to be useful – particularly if you happen to’re brief on clamps. Run a bead of wooden glue alongside the sting of one of many 614” items, then line up that piece and a 1314” piece flush throughout the underside, and flat throughout the panel, then clamp throughout the 2. Drive screws into the pockets to hitch the 2 items collectively. Now that the screws are in place, you may unclamp and transfer on to becoming a member of the 2014” to the 1314” piece. Do the identical with the opposite aspect panel.

Drill the aspect panels. To use pocket screws to help with panel glue-up, clamp the aspect items flat to your bench, and drill pocket holes to hitch the panel items. Here, I’m drilling the center board with one gap 3″ up from the underside edge (it’ll get lower away if you lower the arc) and one other gap 51⁄4″ from the underside edge.

Once your glue is dry, lay the panel screw-side up flat in your bench, and mark the middle level throughout the underside edge (it needs to be at 814“). Now, using an offcut as the base for the compass point, measure 2” down from the middle level, place the compass level there, and draw the arc. Use a jigsaw to chop out the arc (you’ll be reducing away the 2 backside screws), then clear up the lower utilizing a rasp and sandpaper. 

Use a miter noticed to chop the three step helps and again brace to 1534” out of 1×2 (which truly measures 34” x 112“). Clamp each bit flat and drill one pocket gap into the middle at both finish. Set them apart.

Now, out of 1×8 (truly 34” x 712“), lower the three step treads to their closing size of 1814“, then clamp a chunk flat to your bench, with one lengthy edge overhanging. Use your jigsaw to tear every tread to a width of 578“. (You’ll get a straighter lower if you happen to clamp a straightedge in place to information the foot of the jigsaw.) 

Panel glue-up. Use a clamp to carry your panel items collectively as you seat the pocket screws. Once the screws are in place, the clamp will be eliminated.

Now all of the items are prepared for meeting; it is a good time to sand (as a result of as but there aren’t any corners to cope with). Sand over the panel joints to make sure the panels are flat. If you’re planning to color, sand to #120; if staining, you could wish to sand to #180.

Joining the step helps and again brace to the perimeters is a bit tough, involving some artistic clamping and a scrap of two×4. Separate the 2 halves of your Workmate so you may get clamps by way of the center, then clamp the two×Four scrap tight to the desk. Butt the entrance fringe of the underside riser (the brief piece within the panel) flush to the two×4, and clamp the panel to the desk. Hold the step help towards the two×Four flush with the highest of the riser, gripping firmly to maintain it aligned, then drive the screw into the pocket to hitch the help to the panel (see image at left). Reclamp the panel towards the two×Four to connect the middle and high step helps, in addition to the again brace.

Quick and simple screwing jig. A scrap of two×Four is clamped to the Workmate to function a information and help for screwing the step helps and again brace in place on the aspect panels.

Now connect the second aspect panel, utilizing the identical screwing jig. (If your drill is massive, borrow a small one – or use a screwdriver – to extra simply get contained in the workpiece.

Center every tread throughout the steps, drill pilot holes, then nail the treads in place with #6 end nails. Use a nailset to sink the nails under the tread floor, then fill the holes with wooden filler (or spackle), and let it dry.

Once the filler is dry, sand the joint edges and filler flush. Chamfer the entrance and aspect edges of the treads with a block aircraft to maintain them from splintering, and break the again edge with sandpaper. Paint or stain as desired.

Shaker-inspired Step Stool Cut List


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