Author: Dave

Production Technology
What do I do next? Name
1. Grab some knowledge
c Complete all your worksheets about safety, drawing, layout, and math with fractions.
Then get your lumber: c one 8’ piece of 2x6 lumber for the sides and steps
c four 16” long pieces of resawn 2x4s for support slats
2. Cut up your 2x6 into rough lengths on the mitre saw. You will cut it into 6 pieces roughly 16” long.
c 2 pieces 16” long for the steps.
c 2 pieces 16” long for the long sides.
c 1 piece 16” long for the short sides (it will be cut in half later).
c 1 piece 16” long to give back to your teacher
c Write the part name and your name on each piece of wood. For example: “long side 2 — Trenae”
2. Mill your lumber to thickness and width
c Use the jointer to make one face and both sides flat on every piece of wood
c Use the planer to make all three support slats 1/2" thick.
c Use the planer to make the steps to 1" thick. Do not plane the sides yet!
c Use the table saw to rip the wood for the support slats to 3" wide
c Use the table saw to rip the wood for the steps and sides to 5" wide
3. Make the sides
c Use a mitre saw to cut the 16” long short side into two pieces that are 8” long each.
c Glue each short side piece to a long side piece to make the side assemblies:
- make sure that it forms an L shape with the two pieces lining up at the bottom
- make sure that jointed side of both the long and short sides are facing the same way
- use clamps, make sure the pieces line up well, and let dry overnight
c Use the planer to plane both side assemblies to 1” thick.
- start with the jointed side down, get the top clean, and then flip it over
- these are wider parts, so use quarter turns instead of half turns
c Lay out the cut and router lines on your side assemblies
c Use a mitre saw to cut the top and bottom off each side assembly. It should end up 10” high.
c Use a router with a rabbet bit to cut the rabbets that will hold the support slats
4. Shape the steps and support slats
c Use the mitre saw to cut the support slats to 13” long
c Use the mitre saw to cut the steps to 15” long
c Use a router with a rabbet bit to cut the rabbets on each end of the support slats
5. Assemble the step stool
c Put all the pieces together without glue to make sure everything fits
c Put paper down on the workbench and glue together the side assemblies and support slats
c Clamp it up tightly with strap clamps. Check that all the corners line up well and are 90 degrees.
c Now you can add glue to the sides and support slats and attach the steps with clamps
c When the glue is dry, you can lay out the drill holes
c Use a drill or drill press to drill 1/4” or 3/8” holes through the steps into the sides
c Glue dowels into each drill hole to reinforce the joint. Cut the dowel tops off when dry.
6. Sand to smoothness
c Use the stationary sander to quickly smooth your joints. Fill if needed. Let the wood filler dry.
c Use a palm sander to sand from 40 -> 60 -> 100 -> 150 grit.
7. Finish
c Use paint or water-based polyurethane to finish your project. Wait at least 30 mins between coats.
c Sand with 220 grit sandpaper after the second and each following coat.
c Apply 3-7 coats for the best quality.