The Prototype

 It's a stool ..

It's a step ladder. 

How long does it take to switch the configuration?  Five seconds is ample time even if you are timidly slow in doing it.

Full disclosure - it is a prototype only to me because I saw a photo of it from an online store.  I thought it would be a nice challenge to make one. Added to the degree of difficulty is that there were no detailed measurements except for the general height, width and depth.  For a minute, but not one second longer, I thought, "why not just order one"? $90 plus sales tax and shipping.  Nah, that would have been far too easy. And where's the fun in that.

I started with a drawn-to-scale sketch.  Key was to figure out the pivot point of the two steps as to not be encumbered by the rest of the frame.  Based on the photo I tried to configure it by just guessing the layout and from how well the dimension would fit my own personal height and reach.

Our next door neighbor who did a home renovations recently gave me some of the utility shelves they no longer needed.  Some of you who read the previous blog must be wondering, "Is this the same neighbor who gave  their round green marble table top?" The same. If you think we must have such nice neighbors, you are thinking right.  And it's a great neighborhood, too.

Why is this a prototype?  Well, I wanted to see first if I can make it work before using any of my stash of premium wood (have you looked at the price of lumber lately?).  The pine utility shelving is the perfect material for such a trial.  The plan is to make the prototype from which a pattern can be established, the experience in making it shall be the model for how to do it on hardwood later.

So, the creativity on my part here is from improvisation - as a musician would improvise on an existing composition.

It took almost a couple of the shelves to make several long boards ripped on the table saw.  The rails which are the short cross members connecting the legs were mitered to 5 degrees to make the A-frame.

To make quick work of the joinery I opted for pocket screws.  If and when I do decide to make it out of hardwood later, I will definitely use one of the traditional joineries.  Not that there's anything wrong with pocket-hole joinery.  In fact pocket hole joinery is quite strong, given the right circumstances. But aesthetically, it has its downside.

Always checking for fit nd alignment every step of the way.

Below is a key step.  I drilled a quarter inch hole to act as a pivot point to test the rotation of the steps.  I had to make sure there was ample clearance.  It was going to be a trial and error but once was all it took.  Hurray!

After drilling the holes on the legs and the two-step assembly for the connecting rod, a check for fit was needed. 

The frame and step ladder assembly are done.  Another test. And another ..

At last the seat and the two steps were fashioned and attached.

More tests.

One other key element are the spacers (my own idea) along the connecting rod to ensure the step ladder assembly stays centered between the frame legs of the stool.

Beore all the parts were put together ..

Strips of rubber lining on all the feet that make contact with floor were attached with contact cement.  A "drawer handle" attached to the bottom rail of the step ladder assembly makes for easy movement when switching configuration.

Concurrently while working on this project I was also refinishing the outside part of our front door.  When it got too hot outside - scraping and brushing the old finish - I'd switch to the workshop (with AC 😍👍) to work on this. I used a commercial step ladder outside so I thought I'd make a comparison.  The prototype clearly has a smaller footprint but the commercial one folds.  But it is heavier, it even has wheels on the back legs for easy movement.  The prototype gets picked up and carried with one hand on the side.

I originally intended for this prototype to be exactly just that, a model.  Now, I think I can and will fully use it in the shop, as is.  It will be a stool to sit on mostly but I have shelves where some of the stored stuff, including some tools, that will need a step ladder to retrieve them.  This will come in handy.  It turned out surprisingly, deceptively sturdy and stable.  Keep in mind, it will deal only with static load that is on the two steps and perhaps on the seat of the stool. The steps are double plied - surface steps on top of two other boards.  The solid round connecting rod is 1-1/4 inch in diameter. And there are essentially six contact points between the legs and the floor. 

Come to think of it it will also look good as a stepped planter for household plants.  Just saying 😉.