To create a wooden bar stool with a contoured seat, follow these general steps. You’ll need woodworking tools and basic knowledge of woodworking techniques.
Materials:
- Hardwood (oak, maple, or cherry are good choices for durability)
- Wood glue
- Screws or dowels
- Wood finish (stain, lacquer, or oil)
- Sandpaper (various grits)
- Foam and fabric (optional for padding and upholstery)
Tools:
- Saw (circular saw, jigsaw, or table saw)
- Drill and bits
- Router (for shaping the seat contour)
- Sanding tools (orbital sander or hand sandpaper)
- Clamps
- Screwdriver
- Measuring tape and square
- Woodworking compass or template for seat shape
Step-by-Step Process:
1. Design and Measurements
- Start by sketching out your design. For a basic bar stool, the seat should typically be around 14–16 inches in diameter and 1–1.5 inches thick. The height should be around 28–30 inches, but adjust based on your needs.
- Consider the contour: You want the seat to have a comfortable curve that fits the natural shape of the body. Usually, a gentle scoop in the center of the seat with a slight tilt forward works well.
2. Cut the Seat
- Cut a circular piece from your hardwood using a saw (circular saw or jigsaw). You can also use a template to ensure a consistent shape. Make sure the edges are smooth.
- Mark the contour on the seat with a pencil, and use a router with a rounded edge bit to carve out the scoop. This will create the contour that allows for better seating comfort.
3. Sand the Seat
- After cutting and contouring, smooth the seat surface with sandpaper. Start with a coarse grit (around 80), then gradually move to finer grits (up to 220). This will make the surface smooth to the touch.
4. Cut the Legs and Support Frame
- Cut four legs to your desired height (typically around 28–30 inches tall). The diameter or width of the legs will depend on your design, but typically, 1.5–2 inches in diameter works well.
- For the stool’s frame, cut a support ring or cross braces that connect the legs. You may want to cut some angled pieces for extra stability.
5. Assemble the Frame
- Attach the legs to the seat with wood glue and screws or dowels. If you’re using dowels, drill matching holes in the legs and seat before gluing them together.
- If you’re using a ring or cross brace for extra support, install that as well, ensuring everything is square and level.
6. Finish the Stool
- Sand the entire stool, smoothing out the surfaces and removing any rough edges.
- Apply a wood finish of your choice. You can stain the stool first, followed by a polyurethane finish for durability, or opt for an oil finish for a more natural look.
7. Upholster (Optional)
- If you want added comfort, you can upholster the seat. Use a foam cushion and fabric of your choice, cutting the foam to fit the shape of the seat. Staple or tack the fabric to the underside of the seat.
8. Final Touches
- After the finish has dried, give the stool a final sanding with a very fine grit to ensure smoothness. Check for any imperfections and touch them up.
With these steps, you should be able to create a functional and aesthetically pleasing wooden bar stool with a contoured seat.