Step Stools South Bend IN

Inspired by a typical Shaker step stool, this version employs pocket screws to join both the side panels and the supports. To cut down on the number of rip cuts, I used three pieces of 1x6 dimensional lumber to form the side panels (1x6 actually measures 3⁄4" x 5-1⁄2"), so this version also ends up a bit deeper than a traditional Shaker stool – and thus a little sturdier and beefier looking.

First, use your miter saw to cut the 1x6 pieces to length for the side panels. You’ll need two each at 20-1⁄4", 13-1⁄4" and 6-1⁄4".

Now, clamp one of the 20-1⁄4" pieces flat to your bench (face side down), and drill holes for two pocket screws along the edge that will meet the middle piece. Place one hole 2" from the bottom edge, the other at 11". Repeat with the second 20-1⁄4" piece. Now drill each 13-1⁄4" piece along the edges that will meet the short pieces. Locate one hole 3" from the bottom edge, the other at 5-1⁄4".

Next, it’s time to glue up the side panels, and this is where the pocket screws come in handy – especially if you’re short on clamps. Run a bead of wood glue along the edge of one of the 6-1⁄4" pieces, then line up that piece and a 13-1⁄4" piece flush across the bottom, and flat across the panel, then clamp across the two. Drive screws into the pockets to join the two pieces together. Now that the screws are in place, you can unclamp and move on to joining the 20-1⁄4" to the 13-1⁄4" piece. Do the same with the other side panel.

Once your glue is dry, lay the panel screwside up flat on your bench, and mark the center point across the bottom edge (it should be at 8-1⁄4"). Now, using an offcut as the base for the compass point, measure 2" down from the center point, place the compass point there, and draw the arc. Use a jigsaw to cut out the arc (you’ll be cutting away the two bottom screws), then clean up the cut using a rasp and sandpaper.

Use a miter saw to cut the three step supports and back brace to 15-3⁄4" out of 1x2 (which actually measures 3⁄4" x 1-1⁄2"). Clamp each piece flat and drill one pocket hole into the center at eit...