Step On It: A Footstool Project Principles of Manufacturing Copyright © Texas Education Agency, 2012. All rights reserved 1

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Step On It:A Footstool ProjectPrinciples of Manufacturing

Copyright © Texas Education Agency, 2012. All rights reserved

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A footstool is: *functional *simple to construct

*inexpensive

The material used is a 1 X 12 from the lumber yard.


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Alternative Designs

The student can change the end and rail designs to personalize their footstool.


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Footstool Plans


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Pictorial Plan


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Exploded View


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Three View Plans


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Top Plan

11 1/2

143/4


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End Plan

10

8

2 1/2 2 1/2 2 1/2

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Rail Plan

10 1/2

2 3 1/2 3 1/2

2

1


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Bill of MaterialsPart Name

Quality Thickness Width Length Board Footage

Cost

Top 1 3/4 11 1/2 14 1.12 $1.67*

End 2 3/4 10 8 1.11 $1.66*

Rail 2 3/4 2 10 1/2 0.29 $0.44*

Totals 2.52 $3.77*

*Prices will vary


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Simple Production Steps


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Beginning the Project

• Ask instructor for material.• Cut material to the dimensions of the parts.• Lay out the designs on the ends and sides.• Cut the designs. • Smooth the design cuts with a file and

sandpaper.


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Steps in Sanding

• Coarse sand all surfaces of the parts using 80 or 100 grit sandpaper. (removes all saw and file marks)

• Sand all surfaces of parts with 120 or 180 grit sandpaper. (removes coarse sanding marks)


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Placing Screw Holes in Rails

• Use a drill press and drill two holes in each rail to install the top. The hole needs to be counter bored for the screw head.

1 1

3/8


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Counter Boring for Screws

1/8” drill through the rail first

3/8” drill ½ deep in bottom of rail

The counter bore will hide the screw head inside the rail.


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Assemble Rails to Ends

• Nail the rail to the ends with 8d nails.

•drive two nails per rail end

•add glue to the end of the rails


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Mounting Top on Footstool

• Turn the top upside down on the work surface.• Set the end/rail assembly on the top and

measure 1” from all top edges and the assembly. This centers the top on the assembly.

• Install 4 screws into the holes to hold the top to the assembly. The screws are #8 wood screws that are 2“ long. This length of screw will hold the top on the footstool.


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Measuring for Top Alignment • Measure 1” in from each side of the top for placement

of the rail/end assembly.

Top

Rail/EndAssembly

1”

1”

1” 1”


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Steps to Finishing

• Use the 180 grit sandpaper and sand all surfaces of ends and rails after the assembly has been put together.

• Finish the footstool using the steps you learned in the lesson in “Finishing a Project.”


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Resources

• Lumber and Supply Store site• Woodcraft

http://www.woodcraft.com/• Rockler

http://www.rockler.com/• Brazos Forest Products

http://www.brazosfp.com/sitemap.html


http://www.woodcraft.com/

http://www.rockler.com/

http://www.brazosfp.com/sitemap.html

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Resources

• Woodworking Magazine sites• Wood Magazine

http://www.woodmagazine.com/• American Woodworker Magazine

http://americanwoodworker.com/default.aspx


http://www.woodmagazine.com/

http://americanwoodworker.com/default.aspx

Documents

Step On It: A Footstool Project Principles of Manufacturing Copyright © Texas Education Agency, 2012. All rights reserved 1