3D Chair Leg Jig

I wanted to make a stool with the scraps of two different chairs that both had salvageable parts. Another factor was wanting the legs angled out 15 degrees in both the X and Y direction. Since I do not have a band or table saw, this is a very difficult cut to perform. So I made a model in Fusion 360 of the stool and took out the negative space. Then I 3D printed this guide with a hole for the screw mount to keep it in place while being cut. This hole will also be the pilot for the screw in final assembly. This 3D guide was a perfect tool for my hand saw to follow. I labeled each side and how deep the cut would be. I also 3D printed two more since my saw would scrape the PLA edges, which helped made exact, repeatable cuts.

3D Chair Leg Jig

The touching surfaces were then glued up and screwed in the leg to the frame (from the pilot hole). The overhanging lip from the chair leg will be extra support for downward pressure.

The frame was made from 4 pieces of scrap material, which were screwed and then plugged with wooden dowels carved on my homemade CNC machine.

The final result turned out great and does not tip over. Combining CAD, 3D printing, and some hand tools, I was able to create a complex piece from up-cycling household objects.