How To Make Bar Stools
Use a miter saw, circular saw, or hand saw to cut the lumber for the bar stool. Drill pocket holes in all of the boards except the legs and seat boards. Use a Kreg Jig and set it to the 1 1/2 inch setting on both the jig and the stop collar on the bit. Step 3 - Assemble! Use 2 1/2 inch Kreg Screws to attach the front and rear sections of the chair. I'd recommend using wood glue as well.
Here is a diagram showing how the front and rear ladders are constructed. Next attach the four side boards. This will connect the front ladder to the rear ladder. Use a clamp to hold the boards together if needed. I have a set of JackClamps that I use for most projects. Use 2 1/2 inch kreg screws to attach the two 15 inch seat supports. Once complete, attach the seat boards to the supports from the underside using 2 1/2 inch wood screws.
Prior to attaching the seat boards you can lay them out evenly on the top side and glue into place. Let the glue dry and then flip it upside down to attach the boards with the 2 1/2 inch screws. This will make it easy to space out the boards.
Plus, you won't have screw holes showing from the top side. Step 4 - Seal or Stain! Protect and make your new bar stools shine by brushing on a couple coats of Helmsman Spar Urethane from Minwax. If you'd prefer another color or added protection I'd recommend using a deck or fence stain.
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