How to Make a Metal Bar Stool How to Make a Metal Bar Stool

What You'll Need
Measuring tape, pencil and paper
Metal bars, wide and narrow widths
Swivel mechanisms, half or full circle
Screwdrivers, screws and retainers
Seat cushion bases, 1/8-inch plywood
Solid foam rubber cushions
Upholstery fabric of your choice
Industrial stapler
Welding torch and gas tanks
Welder's safety mask
Flame-retardant gloves

Get your family into the kitchen to dine casually with metal bar stool seating. You can make your own custom metal bar stools with inexpensive yet durable materials. Follow the guidelines below to construct unique metal bar stools that bring both style and comfort to your kitchen decor.

Step 1: Decide How Many Bar Stools You Wish to Make

At a kitchen island countertop, you may want just 3 or 4 metal bar stools. At a tall cantina-style table, surround it with up to 8 metal bar stools.

Step 2: Measure the Bar Stool Height and Cushion Depth

Measure from the floor up to 10 inches below the lower lip of the countertop. This is the total height of the bar stool plus its cushion. Allowing for a cushion depth of 3 to 4 inches, measure the height for the bar stool frame, from the floor to either 13 or 14 inches below the countertop. This is how tall the frames must be for comfortable seating.

Step 3: Choose the Style of Metal Bar Stool to Make

Based on your measurements, choose the style of metal bar stool you want to make. It can have a round, square or octagonal seat, and operate with a half circle swivel of 180 degrees or a full swivel of 360 degrees. Choose a bar stool with a seat back for swiveling stools. You can also choose a fixed style, with no swivel at all. These stools can be backless. Choose the metal finish, which should match the other metal hardware in your kitchen. As well, select your cushion fill shape, depth and fabric to cover them. Allow twice the diameter or width of the seat cushion top for upholstery fabric.

Step 4: Cut the Bar Stool Frame Pieces and Construct the Seat Frame

Cut all the leg pieces and the horizontal supports to the lengths desired. Construct the seat frame from the horizontal supports. The legs, swivel mechanism and the seat base will be attached to it, so weld it securely.

Step 5: Weld the Bar Stool Frames Together

Weld the lower legs and footrest crosspieces together next. Add the seat support crossbars so they quarter the external frame. Attach the swivel base securely to the top of the frame, with screws and retainers.

Step 6: Assemble the Seat Cushions and Attach to Swivel Bases

Measure and cut the upholstery fabric carefully to allow at least 4 inches of overlap at the bottom of each cushion. Wrap the fabric snugly around each foam rubber cushion and its plywood base. Staple the fabric firmly to the plywood base with at least 1 staple every 2 inches. Screw the seat cushions to the swivel bases through precut screw holes in the swivel plates.

Step 7: Attach the Bar Stool Backs

Align the bar stool backs with the swivel bases and screw them to the bar stool seats. Place retainers on the screw spindles to hold the screws tightly.

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