StoolScience | Technology | Engineering | Math
Problem The objective of this project was to create a stool that we would be able to take home and use. This meant it would have to be able to hold 300 pounds safely in order for it to be used. The stool also had to be created using only hand tools. Ideas My idea behind creating a stool was not to create a stool that held the most weight, but instead create a stool that functional in design looked elegant and interesting in character something I thought that could not be achieved using common designs. This meant to mean using curves and arches that stayed symmetrical and flowed with the design of the stool. This in mind I aimed to reduce as many sharp edges that I could, except for the top of the stool. Ideas that from my original designs included a hand holding slot, angled legs, and inverted bridge like side panels. However, after multiple tests ran through 3D printing I found that the test models I had created did not amount to what I had in mind. Instead I choose to create legs that retained the original arched design, side panels that ware also curved, and a top that featured sharp slanted sides. This design can be seen to the right. Integration The process of designing this idea was very difficult and started by creating blueprints from the sketchUp models I had designed. After creating said blueprints I added up the total length I would need of wood in order to receive that amount from Mr.Westhafer. After receiving the required length of wood I needed I then began tracing and marking the measurements I needed for each individual piece on the chair. My next step was to start creating my stool, which I began by creating my top. First using a saw to get close to my intended lengths, then using a rasp and file to get precisely the measurement I needed. Next I continued shaping my top by using a rasp and file to get the desired edges and slants that I needed. This step in chair creation cause me many issues due to the difficult technique needed to create the edges. My lack of technique can be seen in the slightly asymmetrical edges in my final design. However, this was the character I was looking for in my chair and seemed to give it something more. The next piece I would move onto is the side panels which I began by creating a traceable representation of the arch I had intended for the side piece. I then used a coping saw in order to come close to my intended lengths. Which I followed by using a rasp and file to get the exact curve and side lengths I needed. The next step was to clamp the two side pieces together to make sure they were both symmetrical and file them down until they were. I then moved onto creating the legs of my stool which I created by tracing the intended radius of the circle on the leg. Then use a coping saw and a hand saw to cut little chunks out from the circle. I then followed this up with a file and rasp to achieve the lengths I wanted for the circle. The next step was to clamp these two identical legs together and make sure that not only that the circular area of the legs were the same but also the feet and top of the legs. Another crucial part of designing the legs was making sure they were both flat on top and bottom, of equal length, and could stand on their own. Once all of this was checked off I moved onto sanding my pieces first starting with very low sandpaper grit (80) and moving up to the highest grit available(220). Making sure to always sand with the grain and removing any slight imperfections. The next step was to start drilling holes in my pieces in order to use pegs to put my stool together and make sure it can hold the intended weight. Second Semester Coming back into the new semester I started where I ended. I did this by first putting one leg with one of my side pieces and then conjoining these pieces together to form what would be the base of my stool. After this I found myself in a sticky situation. A problem I had foreseen, ended up coming to life when I realized that my stool did not have a balanced base. However, with the advice of Mr. Westhafer I proceeded forward by drilling holes in my stool Top and connecting it to my base. As if almost like magic my stool didn't have wobble which meant instead of shaving down the legs of the stool I could move onto sanding down any remaining pegs in my stool. This took me about a day in total leaving me with a product that I could've been proud of, but felt needed a little more. For me this meant staining my stool with a nice dark brown color similar to the color I had been projecting on my sketch up designs. The process of staining took about a day and involved a slow movement of repetitive brush strokes. The staining process started from the bottom of the stool and then moved up as I waited a couple of minutes for the wood to soak up the color from the stain. I then let the stain sit overnight and then returned to a beautiful yet still not complete stool that you can see to the right. As I said the stool is not yet complete and needs a single coat of polyurethane which I applied in the same manner as the stain. In that final step my stool was completely and just needs a little time to dry and to pass the three hundred pound stress test. Conclusion After the nail biting three hundred pound test my stool came out successful. During the test no sharp noises or indication of breaking was shown in the stool meaning that I was able to take it home. This test allows me to conclude that the stool is reliable. However, the test did not allow me to identify its dynamic stress capacity which may mean stool failure if someone were to jump on it. Overall I felt the problem we were handed really gave me a better understanding of the process that goes into making something and more appreciation of someone who works by hand. ___________________________________________ OVERVIEW ___ Problem: Create a stool that can hold 300 pounds using only hand tools and wood Constraints: -Only hand tools -Time Tools: -Ruler -Plane -Tri-square -Clamp -Rasp -Saw -File -Wood -Coping Saw -Safety Glasses -Pencil -Paper Ideas: -angled legs -arched side panel -curved top edges -inverted bridge side panel -sharp top edges -circular leg design Final Idea: -Final idea can be seen on the right and implements a long top with a bevel, with a arch like pattern carried throughout the design(seen in the legs and side panels) |