SUTTON OUTDOOR BAR STOOLSINSPIRED BY BALLARD DESIGNS BUILT BY: CHAD STARLIPER

STORY

• Wanted a console bar table for back porch. Copied the Ballard Designs Sutton Console Bar Table.

• Needed stools to match, so I free designed some outdoor stools that would go with the table.

• Was going for an outdoor teak look, so went with slatted seats and a light colored Minwax pine stain. Added some curved aprons for some flare.

• I was building three stools, so did a lot of the cutting and other tasks at once… and the cutting took a long time.

CUSTOM OUTDOOR “SUTTON” BAR STOOL26 1/2” H X 17 1/2” W (SQUARE)

SHOPPING LIST (PER STOOL)

Lumber

• 3 - 2x2 (I ripped 2x4s into 2x2s because the 2x4s are cheaper and better quality wood, and needed neat straight boards for legs)

• 1 - 2x4

• 2 - 1x2

Supplies

• 120 grit orbital sand pads

• 220 grit sandpaper

• Wood glue

• Wood filler

• 2 1/2” PH screws

• 2 1/2” wood screws

• 1 1/4” 18 GA brad nails

• Wood conditioner

• Wood Stain

• Foam brushes

• Clean rages

Tools

• Orbital sander

• Long clamps

• Drill

• Countersink drill bit

• Kreg jig

• Circular saw

• Table saw (optional)

• Jig saw

• Carpenter square

• Tape measure

CUT LIST

• Legs (4) - 2x2 @ 25 3/4”

• Leg braces (4) - 2x2 @ 14 1/2”

• Seat supports (2) - 2x2 @ 14 1/12”

• Short side aprons (2) - 2x4 @ 14 1/2”, rip cut 3/4” from one side to allow for top seat slat

• Tall side aprons (2) - 2x2 @ 14 1/12”

• Long seat slats (2) - 1x2 @ 17 1/2”

• Short seat slats (8) - 1x2 @ 14 1/12”

• *** Optional apron curves: trace semi-circle on bottom half of each apron with edge of circle 2” from each end (see picture)

ASSEMBLE LEG FRAMES

• Place the pieces face down (so the inside is accessible)

• Drill 1 1/2 PH in each end of smaller side apron (that was ripped smaller)

• Attach to legs using 2 1/2” PH screws making sure the top and outside edges are flush

• Make two sets of leg frames

• (I always clamp tight and ensure all pieces are on flat surface before attaching to make sure to get a perfect flush fit)

ATTACH SIDE LEG BRACES

• Drill 1 1/2” PH on underside of 2x2 leg braces

• Attach to inside of leg frame using 2 1/2” PH screws

• Do for each leg frame

• I chose to put these side braces 10” from bottom of legs to underside of brace (personal preference, the front and rear will be 6” from top of brace to floor for foot rests)

FINISH WOOD

• Because these are slatted tops for the outdoor style, I learned from experience to stain all the wood before assembling

• Sand all pieces with 120-grit sand paper using orbital sander

• Prepare with wood conditioner

• Stain to suit

ATTACH LONG TOP SLATS TO TOP OF FRAME APRONS

• Lay leg frame face down

• Using wood glue, attached 17 1/2” top slats to top of leg frames

• Ensure flush with outside edges that will show

• Clamp for 10 minutes for glue to bond, then finish with 1 1/4” 18GA brad nails

• Do same for each frame

ATTACH SEAT SUPPORTS

• Attach 2x2 seat supports to inside of leg frame aprons (the top should be even with top of apron, but below the added top slat)

• Pre-drill 3 holes and follow with #8 countersink bit

• Use pre-cut seat slats to check for placement to ensure the supports will allow for a flush fit when the seat top slats are added on top

• Attach support to apron with 2 1/2” wood screws, countersinking to bury the screw heads

MAKE SURE CHILDREN HAVE FUN

• My little girl just likes to hang around and watch daddy do

• It was a cold windy day so she wanted to wear daddy’s sweatshirt

• …OK back to work

ATTACH APRONS TO LEG FRAME

• Lay leg frame face down

• Drill 1 1/2” PH in both ends of remaining 2x2 side aprons

• Attach side aprons to inside of legs beside each seat support

• Ensure aprons are flush with top and outsides

ATTACH LOWER LEG BRACES

• (Sorry for the bad picture)

• Leaving leg frames as is after attaching 2x4 side aprons to legs…

• Drill 1 1/2” PH on both ends of underside of two 2x2 leg braces

• The top side of the braces should be 6” from the bottom of the leg (preference)

• Ensure outside edge is flush, then clamp to keep flush before attaching

• Attach braces to legs using 2 1/2” PH screws

ATTACH FRAMES TOGETHER

• Lay the bare leg frame face down

• Lay the other leg frame, the one with braces just assembled, on top

• The 2x4 side aprons should fit onto the legs just around the seat support of the frame sitting face down.

• Ensure aprons are flush with top and outside edges then clamp to keep from moving

• Attached each apron to leg using 2 1/2” PH screws (I used impact driver because it was hard to get in there, but be careful not to overdrive the screws!)

ATTACH LEG BRACES TO BOTTOM FRAME• This is the last step to complete the base

of the stool

• Keeping the frames in the same place as when attaching aprons to legs in prior step…

• Fit the lower leg braces so they are 6” from bottom of legs and flush with outside edge

• Clamp in place to prevent movement, as the tongue of the prior assemblies will pull the legs away from location

• This will also serve to “square up” the stool

• Attach braces to legs with 2 1/2” PH screws

FINISHED BASE

• The base is finished

• It should look like this

• You can see where the remaining short seat top slats will lay on the inside 2x2 supports added earlier

ATTACH SEAT TOP SLATS

• There should be 8 seat slats @ 14 1/2” remaining

• Space slats approximately 3/8” apart (o whatever fits best — I used the eyeball method)

• Glue each side of the slat and place onto seat support

• Clamp in place for 10 minutes while glue bonds

• Use 1 1/4” brad nails to finish attaching slats, using 2 nails for each piece at each end, nailing into the support

FINISH UP!

• Fill all nail holes and “fit” imperfections with wood filler

• Lightly sand filler spots smooth with 220-grit sandpaper by hand

• Reapply “spot” stain where needed to hide wood filler areas