Puzzle stool

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Project by BettansBygg posted 570 days ago 1010 views 14 times favorited 11 comments Add to Favorites Watch

My sister-in-law saw one of these in a store where they would customize a stool with your child’s name in removable letters. But they cost more than 200 usd and she thought that was kinda pricey, so she asked me if I could make one.

I used the scrollsaw to cut out the letters. I sanded them using a dremel drum sander in the drill press, that was perfect for sanding the small radius curves. I then laid the letters on a piece of scrap mdf, traced around them with a washer (because of the guide bushing) to get a template for routing the hole in the stool top. The legs attach to the top with tenons. Then finished with a waterbased paint. My version including paint cost less than 20 usd.

-- Lisa

11 comments so far

View Diggerjacks's profile


1743 posts in 1770 days

#1 posted 570 days ago


This is a very sympathical idea

A nice work

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View Vicki's profile


937 posts in 1975 days

#2 posted 570 days ago

Fabulous job. I love it.

-- Vicki on the Eastern Shore of MD

View a1Jim's profile


112014 posts in 2208 days

#3 posted 570 days ago

Very creative idea and a super cool build great job.

-- Custom furniture

View nittanylion's profile


53 posts in 2420 days

#4 posted 570 days ago

What kind of wood did you use? Can you message me or write about how you used the washer?

View iamcliff's profile


471 posts in 783 days

#5 posted 570 days ago

Cool idea.

-- Chris, , FACEBOOK: , Proverbs 16:9

View BettansBygg's profile


7 posts in 577 days

#6 posted 570 days ago

- nittanylion

Since they wanted it painted white I just used some 25 mm (1 inch) thick MDF I had left over from another project. The letters are made from 10 mm (3/8 inch) thick MDF.

About the washer thing, I’m really bad at explaining things so if anyone is more gifted with words than I am feel free to jump in.

Since I use a guide bushing on my router when template routing, the template (in this case) has to be bigger than the letters because there’s an offset between the router bit and the guide bushing on the router. (The offset is the diameter of the guide, minus the diameter of the cutter then divide by two)

Use a washer with a metal width equal to the offset. Then put a pencil in the washer hole and roll the washer against the edge of the letters tracing around them. The washer can’t go into sharp corners so you have to draw some lines by hand (the red line in the third picture below).

In my case I wanted some air around the letters so they would be easy for a child to remove and put back (I also needed some room for paint) therefore I used a washer that was wider (offset = 3 mm, washer metal width = 4 mm).

Here are some pictures that might help

Here’s a picture of the finished template and the letters

-- Lisa

View BroncoBrian's profile


76 posts in 589 days

#7 posted 569 days ago

I want to show my wife this project, she will love it, but then I might be making one which for $20 sounds good, but I assume you were not done in an hour…..

-- Stop thinking, let things happen... and be the ball.

View BettansBygg's profile


7 posts in 577 days

#8 posted 569 days ago

I spent two days building it, but I wasn’t working nonstop so I don’t know how many hours it actually took. Then it took a week to paint it. I’m really slow when it comes to painting things. Never satisfied. I hate painting.

I only charge for materials when building stuff for family. Or not, most of the times I’ll just give them away for free. I’ll have to be better at charging people for the things I build.

-- Lisa

View TFox's profile


2 posts in 98 days

#9 posted 4 days ago

What font did you use? Looks amazing! I am sure your daughter loves it!

View BettansBygg's profile


7 posts in 577 days

#10 posted 2 days ago

The font is Cooper Black

-- Lisa

View TFox's profile


2 posts in 98 days

#11 posted 1 day ago

Very cool!

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