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Build something unique and add an extra personal touch to your home with this vintage inspired, European type stool. This DIY project is sure to impress and is easy to create with a welding machine, metal and these step by step instructions.

Forney Industries teamed up with Joe Mooney from Homesteadonomics to create an industrial stool that Mooney could use for his home office. Mooney searched the internet for some inspiration and decided on a design that would be practical for the whole family.

Tools and Materials:

Project Prep:

Remember to practice safe metalworking habits by wearing the proper personal protective equipment. A fire-resistant welding jacket or apron and sleeves, welding gloves, safety glasses and a welding helmet will keep you protected from harmful arc flash and sparks.

The seat portion of the stool depends on your comfort needs. Mooney created a wooden seat for his stool (see how on his Homesteadonomics YouTube channel) but a fabric or repurposed seat could also work.

Step by Step Assembly:

Start by cutting 4 triangle gussets about 2”-3”, or to a size that will fit the length of the coupler nut out of scrap metal. 

Triangle Gussets

Take a 5”x 5” piece of scrap metal and mark the middle as to where you will put the coupler nut. This will be the connection from the seat to the base.

Lay out your triangle gussets and the coupler nut on the 5”x 5″ steel plate where they are evenly spaced.  You may find it helpful to align them with the corners of the 5”x 5” piece of scrap metal.

Aligning Triangle Gussets

Tack weld the coupler nut into place, and then add the triangle gussets. Ensure the coupler nut is square to the metal plate as this will ensure the stool seat will end up level.

Pro Tip: Use magnets to keep the coupler into place while you tack weld.

Magnets to hold Coupler in place

Once your tack welds are done, go back and make full welds along all sides of the triangles.

For the base of the stool, weld a nut inside of a pipe. This is the main function of the stool.  The inside diameter of the pipe should allow the nut to snugly fit inside. Some light sanding may be required to fit.  When welding the nut, it may distort some of the inner threads. You may have to re-thread the nut if this happens.

Nut to be welded inside of Pipe

For the lower part of the stool, use magnets and clamps to position the entire assembly vertical.

Before placing the legs to the stool, cut the tube steel at a 45-degree angle to attach to the base of the chair.

Getting the stool legs in place

Use your judgment when placing the legs as to which angle you would like them. Tack weld the legs to the base of the chair. Use the magnets to keep the legs in place. Finish off the legs with a longer weld to keep the legs stable.

Tack weld legs

Take a sanding disc to clean up any imperfections or mistakes.

Cleaning Imperfections with Sanding Disc

To find out the angle of the legs for the bottom, dip each leg into a shallow container of paint as the stool sits on the floor. The paint edge will create a level mark showing where to cut.  This will create a flush finish to the floor.

Dip legs in paint to determine cut

Weld the washers onto the bottom of the legs as well as the top of the base for the stool. Use a sanding disc to clean up any imperfections.

Paint the base whichever color you choose.

Paint stool base

The final step will be to drill mounting holes in the base plate for your seat to attach. Then you can twist on the threaded rod and take a seat.

Mount base plate
Completed Bar Stool

Welding and metalworking can add some unique aesthetics to your home. Whether you’re wanting to create some décor for your walls, or build one of a kind furniture, a welding machine can offer many possibilities. Learn more about the products used for this project by clicking the button and check out Homesteadonomics’ YouTube channel for more videos.