Another fun project it is. But then again, they all are.
I finished the tenons on the band saw. Never did it that way, so I had to try it. Worked out great after getting the saw set up. I then did a dry fit and used a wood bow to draw the arcs on the top and bottom rails. The band saw was used to cut them, and the sander cleaned them up.
Now it's time to drill some holes. In the legs are 3/8" holes drilled all the way through. The steps have 1/4" holes for the steel pegs. This is done so the steps will rest on the cross pieces and not have the pegs carry the load. I should note here that cross braces are cut at a 15º angle so the steps will rest firmly on them. WHen drilling the 3/8" holes, I goofed and made upper holes in the back legs. Not needed as the top step only pivots in the front. I'll have to make some plugs for fixing my mistake.
The bottom step is put together using 4" strap hinges. You butt the 2 parts together, drill the holes using a hinge centering drill, and screw them on.
NOTE:Be aware of the orientation of the angles on the leg bottoms. Angles of 15º are cut there, and the cross brace tops.
The hinges for the legs are 2" cabinet hinges. Attach them to the rear leg tops, align the legs to the front legs, clamp a block to the front legs, remove the hinges from the rear legs, attach them to the front legs, and re-attach them to the rear legs. Whew.
A 3/8" roundover bit was used on the bottom edges ofsteps where the pivot pins are. A 1/8" RO bit was used on the other step edges.
A dry fit of all parts, and it is starting to look like the step ladder it's meant to be.
Last edited by AxlMyk; 07-11-2009 at 02:35 PM.