I continued to trim the piece of sheet metal. I used a Beverly shear to cut along the lines I sketched on the metal.
I used two different files to sand the edges of the metal leg. The first file was more coarse than the second. I used sandpaper to refine the edges.
I used the break, shear, and roll machine to bend the metal. The angle of the bend was approximately 90 degrees.
I used a body hammer to flatten the upper end of the stool leg. I attempted to straighten out the end of the leg so that it could be attached to the chair.
I used an old stool leg as a template. I continued replicating the shape of the old leg by hammering the sheet metal on different surfaces.
I hammered the lower end of the stool leg. I hammered the metal on different surfaces to duplicate the original design.
Before attaching the leg, I used sandpaper to remove the rust surrounding the corner of the stool. I used coarse sand paper to remove and flatten large metal bumps.
I used files and sandpaper to flatten and sand down the corner of the footrest. Sanding down the corner made welding the replacement leg easier.
I used clamps to hold the leg in place. I double checked my initial measurements and made sure each leg was the same length.
My teacher welded the new leg to the stool. He added welds along the footrest and the upper stool corner.
I sanded the bottom of the stool and removed a large layer of rust.
Although the new stool leg was now attached, the thinner material meant that it was still weak.
I used cardboard models to test out different ideas. I brainstormed different methods of making the stool leg stronger.
