Haven't posted in forever, but here is my stool I made, posted about it in my garage many moons ago....
Quick Project: Keg stool
Quick project. I have been meaning to build a shop stool out of an old empty keg I have been dragging around for years, and finally got it done.
The first challenge was finding foam that was dense enough, most shop stool i sit on and the foam bottoms out. I went to fabric store and found vinyl remnant to cover seat for $3, and I tried all the foam they had there, even the densest foam was not all that dense, and it was not cheap either.
So I left, and searched on for the right type of padding, after squeezing everything i could find i bought a thick yoga mat from Joblot for $10, and cut it into 4 section i glued together to get me about 2.5 inches thick. I used spray glue to glue the 4 sections together after i rough cut them.
once glue setup, i used keg as a template and cut out foam about 1/2 wider than keg, jig saw worked well for this
Next i cut out plywood to fit keg
I then cut some 2x3 and fit them to bottom of plywood for a tight friction fit with keg
then I glued foam to seat
While that setup I decided to clean up keg a bit, I peeled off stickers and sanded it with 80grit pads on random orbit sander
Here it is before
Half way done
Finished. I was shooting for a brushed look, not perfect, but 100% better for about 30 minutes of sanding
Next i let vinyl warm in sun, then stretched and stapled it to the seat
Here is finished product, perfect height for 37 inch benches like i have. Seat is firm enough for the largest of large guys while still being comfortable. Total cost since keg was free and wood was scrap was about $15
