I’ll be adding a weekly version of Freebie files. Enjoy
https://drive.google.com/file/d/1Ce91gjRQhL1Q2yPLpDLOOvdZmjfv-Fwt/view?usp=sharing
This is a easy step stool to get you started into furniture. This is intended for 3/4″ plywood. might need a few tweeks to fit it tight.
Materials
1/2 sheet of 3/4″ Plywood
qty 18 x 36″ 3/4 diameter dowels
source for dowels
https://www.caseyswood.com/shoppingcart/zen-cart/index.php?main_page=product_info&cPath=346_146&products_id=1704
$1.34 ea, good quality
bits required, 1/4″ end mill
Start by measuring the diameter of your dowels, ( note they will probably vary a bunch )
place one of the files on a piece of scrap ply and experiment with offsets until you get a good friction fit for most dowels. ( make a note of the perfect offset, we will use that later )
Cut all dowels exactly in half
Chamfer the tips of each dowel on a belt sander
I double sided tape or tape and CA glue the board to your spoil board
A1 and B1 are full depth through holes, in my aspire file, i pocketed an offset and then did a final .004 finish cut inside.
A2 and B2 are 1/4 pocketed holes
Size A1 and Side B1 are full depth through holes.
Side A2 and Side B2 are 1/4 pockets
I used 1/4 passes followed by smooth finish pass.
Using 4 * 2″ long spare dowels ( sanded down to be a very light friction fit ) dry fit all 4 ply elements together using the dowls to secure the extents and the corners then sand till you achieve the finish you desire.
Glue and assemble with plenty of clamps.
To avoid glue buildup in the holes preventing the dowels from seating properly glue together side_A1 + side_A2 and seat the dowels in one operation before doing the same for side_B1 + side_B2.
Clamp across the width off the chair , and also pay attention to make sure each side has adequate clamping pressure.
Avoid clamping under the base of the chair so you can true up the sides by resting the chair standing upright overnight.