I was given a few 90 x 180 cm (3 x 6') sheets of slightly used plywood which I am in the process of repurposing.
Since I have use for a couple of extra stools occasionally, I recently drew this slotted (flat pack) stool in Sketchup.
I designed it so that two complete 48 cm tall stools will fit onto a 90 x 180 cm (3 x 6') piece of 12 mm (7/16") plywood.
It could easily be cut with a laser, or a CNC router (I cut it manually with a jig saw and a circular saw).
(Click on the [i] at the top left of photos to see an enlarged version.)
- 90 x 180 x 1.2 cm piece of plywood (slightly larger than 3 x 6' and 7/16" thick)
- Handheld circular saw
- Handheld jig saw
- Power drill (and 8 mm bit)
- Small orbital sander
You can cut it yourself, or have Ponoko do the production for you.
Step 1: Plywood stool plan layout
I designed this stool so that two could be made from one piece of 90 x 180 x 1.2 cm plywood (they will fit onto a 4x8' with room to spare).
I have attached an EPS outline file to the first step, and it could be converted for use with a laser or CNC plotter.
*Note that the slots are made for 1.2 cm (7/16") plywood.
Step 2: Cutting out the pieces of the stool
I used CorelDraw to output the outline in tiled format onto sheets of paper as I would be cutting the pieces by hand.
If you use paper templates, tape them down as any movement means the shape and measurements will be distorted.
I used a circular saw for straight edges, and a handheld jig saw for the curves.
For the slots on the seat piece, I drilled holes near the ends of each slot, then inserted the jig saw into the holes and cut them out.
After cutting out the stool pieces, I used an orbital sander to clean up the surfaces and edges.
Step 3: Assembling the stool
The two wider leg pieces (front/back) slot into the narrower leg pieces (left/right) from above.
Since they are slightly angled outward (for better stability), it will require a bit of back-and-forth movement to get them to fit.
Next, all you have to do is pop the seat piece on, and you're done.
As an alternative to the slots on the seat piece, you could use a router and cut in halfway on the bottom side for a clean top side.
(Don't forget to remove the excess amount on the tabs at the top of the leg pieces if do this.)
I think I will try this method on the next one, and maybe paint it as well.
The last photo is a scale model I made from 3mm thick card stock to check the build before moving on to full size.