1 - Jim McCallum's Weebly
_________________________’s ProjectUtility Stool ProjectGrade 10 WoodworkingCreate a Bill Of Material (B.O.M.) for the stool projectMake sure you check each box “AFTER” item is completedAlways remember to put your name on all your partsYou can make the subparts in any order. Think of each element as a specific project. Following, each subpart is listed with their specific instructionsLEGS Obtain material to fabricate legs from the teacher, check your Bill of Material to ensure you are receiving the correct materialUsing 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-sawJoint 1 surface and 1 adjoining edgeEnsure that jointed surfaces are 90 degrees to each other, if not, they must be corrected. Check with the teacher if you cannot obtain 90 degreesMark the jointed surfaces with an arrow and a pigtailArrange your leg blanks so that all arrows are on bottom and pigtails are on the right side of the blanksSet up planer and run all 4 legs throughRotate legs to that arrows are on the left now and pigtails are on the bottomRun legs once more through the planerAdjust planer to remove 1/16” (one full turn)Run legs through the planer againRotate legs so that arrows are back on the bottom and pigtails are back on the right sideRun once more through the planerREPEAT this process until legs are to the correct width and thickness. THEY MUST BE THAT SAMEUse the following steps to cut your legs to the correct length and angleSet 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 settingReset saw blade to 6 degree to the left of horizontalFlip plank end to end and cut other end at 27 ?” in lengthUse the following steps to prepare legs for drilling and to drill the holes in the legs for the spreadersRemove 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 video485203516256000 holes for the spreaders into the legsInstall a 5/8” diameter Forstner bit into the drill pressEnsure drilling jig is set so that the bit is in the middle of the leg and a depth of 7/16” has been setWith 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 settingAgain 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 classCrossbarsObtain from Mr. Mac 4 pieces of the correct material to be used as crossbars, also known as spreadersIf 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 BacksawUsing a ?” Roughing Gauge, “rough” each piece to create an “ALMOST” perfect cylinderUsing the template and a pencil, mark the out to out length and center of each pieceUsing a parting tool and the template as a guide, turn each spreader to the required dimensions5/8” on each end and 7/8” in the middleUsing a ?” 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 spreadersWhile the spreader is turning on the lathe, make lines approximately ?” apart from the do not cut lines to each end of the spreaderAgain with the Spindle Gauge, taper each end to match the 5/8” diameter you cut earlierUsing 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 diameterUsing Vernier Caliper set to exactly 5/8”, check end diameter of each spreader and adjust as necessary using 80 grit sandpaperFinish sand all the crossbarsSet aside somewhere safe like your locker or backpackSEATObtain enough of the correct 1” thick material from the teacher to fabricate your seatCrosscut where marked by the teacher to create 14 ?” lengthsSet the fence on the General Band-saw to 1 ?”and cut your 1” thick stock. You should end up with approximately 14 pieces that are all 1 ?” wideWith the 1 ?” width standing upright, lay out your pieces to form an interesting patternYou may add other wood to create an even more interesting patternDraw 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 surfaceCheck for perfect jointing between all pieces, re-joint where necessary. Get this checked by teacherObtain 3 large bar clamps and prepare to glue the seat blankSet clamps to correct opening so that all your pieces will fitPut one clamp on the floor (this will be used shortly)Lay paper-towel on the desk under the clamps to collect glue drippingsGlue all pieces togetherWith the clamps set as far apart as possible, tightly clamp the two bar clamps ensuring the underside of all the pieces are aligned flatWipe off all excess glueAdd the third clamp to the top and tightenFlip the blank over and wipe off remaining excess glueClean up all your paper towelsNext class, remove the clamps, clean them and then put them awayPlane the blank to 1” thicknessOn the underside of your balnk, determine center and drill a ?” diameter hole to a depth of approximately 1/4”Set up the circle cutting jig on the Grey Delta Band-sawUsing 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 marksUsing a rasp, rough out a rounded edge on the top of your seatUsing a smoothing file, smooth over the rounded edgeWith a Random Orbit Sander, fully sand your seat starting with 80 grit, then 150, finishing with 220.With a ? sheet (square) sander, polish the edges of your seatIf you still see any un-sanded areas, go back to the 80 grit and fix as requiredGet the seat checked over by the teacherWrap the seat in paper towels, put your name on it and set it aside in the storage shelves for your classUPPER SEAT SUPPORTObtain 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 planedJoint one edgePut your name on it and set it aside with your seatLOWER SEAT SUPPORTObtain correct material from the teacherrough cut this stock to 12” x 6”Using the milling wood steps, make this board exactly ?” x 5” x 5”Do not throw out the offcut, you can use this if something happens to your original pieceInstall “Riving Knife” into a table-sawSet blade height to 1 ?”Perform all table-saw pre-checksUsing the lower seat support jig, create corner notches in the lower seat supportCompletely sand everywhere except the notchesPut your name on it and set it aside with your seatASSEMBLYYou can now cut the ends of your spreaders on the grey Delta band-saw and “gently” grind off the burrs with the 1” belt sanderObtain:a role of clear packing tapethe assembly blockyour legsyour lower seat supportArrange legs into correct orientationPlace the lower seat support and the block into the legsTape the top of the legs tightly togetherTape the lower seat support into position so it can’s fall outInstall the spreadersWrap tape above the legs to hold the seat base togetherWhile 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 screwsUsing the upper seat support material you prepped earlier, follow the video below to make the support to the correct size485203533020000(See video for help with this). Use Link below or scan QR code for video drill and install the upper seat support, follow the video below28003513716000 all the tape and lower seat supportSand the top of the legs to match the upper seat support, starting with 80 gritUsing 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 SEATThe following video can also be used as reference for installing your seat46234355842000 the following:8 – 1 ?” deck screws1 ?” shallow countersink drill bit?” assembly dowel?” drill bitplace seat upside down on a sanding matplace dowel into ?” hole in seatdrill ?” hole into middle of the upper seat supportturn base upside down and place onto dowel pre-drill countersunk holes into seat using holes in upper seat support as a guideInstall 4 - 1 ?” deck screwsMark lower seat support for drilling as per drawings at the end of the plansInstall lower seat support, tap in with mallet if necessaryCountersink drill holes through lower seat supportAttach with 4 - 1 ?” deck screwsOnce seat is installed, use flush cut saw to carefully cut plugsLay seat onto its sideLean against the seat to stabilize and,Carefully cut plugs using a flush cut sawOnce 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 sandingLast chance for any final sanding.Remove seat, and prepare for oiling, you will need the followingDanish Oil containerDanish Oil canGlovesPaper towelFlame tamer for disposalApply oil, let sit for 20 minutes, then wipe off completely a minimum of three times (DO NOT apply oil three times)Re-attach seatTag with you nameComplete Self-evaluationHand in for markingStool is complete, YEAH!!!!! ................
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