Kids’ Step Stool – Metric

Instructions

1. 1Start with the Outer Sides

   • Cut four Outer Sides to length from a 19x89mm board, as shown in the cutting diagram.
   • Then, clamp two Outer Sides together and drill a 38mm hole where shown. Do the same with the other Outer Sides. When the step stool sides are fully assembled, these holes will become the outer ends of the handle holes.

2. 2Make the Other Side Parts

   Cut two Side Handles from a 19x38mm board, then cut and two Center Sides from a 19x140mm board, as shown in the cutting diagram. With your pocket hole jig set up for 19mm material, drill pocket holes in the Side Handles and the Center Sides where shown.

3. 3Assemble the Sides

   • Now you can create the side assemblies.
   • Start by attaching the Outer Sides to the Side Handle and Center Side, as shown. Secure the pieces using 32mm coarse-thread pocket-hole screws.
   • Glue pocket-hole plugs in, and then sand the plugs flush.

4. 4Shape the Sides

   • Now you can lay out the curves on the side assemblies. Using a compass, mark the upper corners as shown.
   • Then mark the lower arch.
   • Cut these curves with a jigsaw, and then sand the cut edges smooth. This is also a good time to round over all of the sharp edges by sanding them. You’ll want to start with coarse sandpaper, such as 80-grit, to remove material.
   • Then use finer grits (100 or 120) to smooth the surfaces.

5. 5Make the Seat Parts

   Cut two Outer Seats and one Center Seat from a 19x89mm board, as shown in the cutting diagram. Drill Pocket holes in the Outer Seats where shown.

6. 6Assemble the Seat

   Attach the Outer Seats to the Center Seat using 32mm coarse-thread pocket-hole screws, as shown. Then round over the edges of the seat assembly—but not the ends.

7. 7Make a Seat Support

   Cut the Seat Support to length, as shown in the cutting diagram. Then drill pocket holes where shown.

8. 8Attach the Seat Support

   Secure the Seat Support to one side assembly where shown using 32mm coarse-thread pocket hole screws.

9. 9Add the Seat

   Attach the seat assembly to the side assembly and to the Seat Support with 32mm coarse-thread pocket-hole screws.

10. 10Add the Final Side

    Secure the other side assembly with 32mm coarse pocket-hole screws as shown.

11. 11Paint or Stain the Step Stool

    With assembly complete, you can paint or stain the step stool. Before that, if you want, you could plug the remaining pocket holes. They really don’t show, so this is up to you. If you choose to fill them, you’ll need 16 more plugs.