Choosing the Right Stock for Your Wooden Step Stool Cow

Another two wooden step stool cows were made from the remains of a damaged table, the right stock was Tasmanian Huon Pine, also known as “shipbuilders gold”, it is lightweight, easy to work and just superb to look at, but today it is a rare and expensive commodity, unless you are lucky and have friends with connections to Western Tasmania.
If you are keen and just a bit adventouros, have a holiday in Tasmania and Visit the town of Strahan. Here, next to the wharf, there is a sawmill specializing in Tasmanian Huon Pine and a few other rare stocks. Whilst in Strahan, take a day cruise to the Gordon River and witness the rare and mighty live Tasmanian Huon Pines personally. Or experience the most unusual and interesting steam-train ride to Queenstown.

Back to the right stock.
As Geppetto was a keen recycler, he almost always used whatever was available from the bush, the tip, factory rejects, packaging, construction site wastes etc.

One day, thanks to the kind help of a friend with a ute or pick-up, Geppetto visited the local newspaper mill which imported machinery from a Scandinavian country, the machines being packaged in crates made of good quality, waterproof plywood. He was able to get some boxes and crates for free. Geppetto made only a handful of wooden step stool cows using the good plywood, the bulk of the stock was used to improve his modest home.

Exterior plywood proved to be the right stock for the wooden step stool cows, it is strong, lightweight and form-stable.

When Henry took on the quest to continue the production of the wooden step stool cows, apart for a few failed experiments, he used almost exclusively exterior grade plywood. More recently Henry became addicted to rare woods, see note at the bottom of the page

What Kind of Plywood?

Care must be taken when selecting plywood. There are many types of plywood panels that are suitable for the cow shaped step stools. Your choice will be affected by both cost and availability. It is worth taking some time to review the choices that are available.

The American Plywood Association (APA) is a non-profit trade association whose member’s mills produce approximately eighty percent of the structural wood panel products manufactured in the United States. The APA, together with the National Bureau of Standards and lumber producers, distributors, consumers and users, has established voluntary standards for grading and specifying lumber manufactured in USA and Canada. Most of their guidelines are applied Worldwide.

Exterior-type plywood - The APA Standard classifies plywood panels into two types: interior and exterior. Interior-type plywood should not be used for the wooden step stool cows or any other project which might be used outdoors. The APA defines Exterior-type plywood as plywood, which will retain glue bond when repeatedly wetted and dried.

Understanding Plywood Veneer Grades - The term “grade” may refer to panel grade or to veneer grade. Panel grades for exterior plywood panels are generally identified in terms of the veneer grade used on the face and back panel (i.e. A-B, A-C, B-C, etc.).
Veneer grade define the appearance of the veneer. The highest quality veneer is “N” grade. “N” grade veneer is used in furniture grade plywood. “D” grade veneer is used only in panels intended for interior use or applications protected from permanent exposure to the weather. For exterior plywood, “A” veneer is highest grade, and the lowest is “C”.

Veneer Grades

Grade A Veneer – Must be firm, smoothly cut, and free of knots, pitch pockets, open splits, and other open defects. Synthetic fillers may be used to fill small cracks or checks. Up to 18 patches are permitted to repair veneers with knotholes or other defects.

Grade B Veneers - Must be solid and free from open defects and broken grain ( except for some small splits not wider than 1/32 inch (0.8mm), and horizontal or surface tunnels no more than 1/16 inch (1.6mm) across, 1 inch (25.4mm) in length, and up to 12 in number. Minor sanding and patching defects, including sander slips, shall not exceed five percent of panel area. Synthetic fillers may be used to fill small cracks or checks. Knots are permitted if they do not exceed 1 inch (25.4mm) as measured across the grain. Knots must be sound and tight. Pitch streaks must not exceed 1 inch (25.4mm) in with. Discolorations are permitted.

Grade C Veneer - Sanding defects that will not impair the strength or serviceability of the panel are permitted. Knots must be tight and not more than ½ inch (12.7mm) across the grain. Open knotholes, usually not exceed 1 inch, are permitted. Splits up to ½ inch in with by ½ panel length 3/8 inch (9.5mm) in with by any length are permitted.

Grade C Plugged Veneer - May contain knotholes and open defects not larger than ¼ (6.35mm) inch by ½ inch (12.7mm). Sound and tight knots up to 1-1/2 (38mm) inches measured across the grain, splits up to 1/8 inch (3.2mm) wide, plugs and patches.

Exterior-Type Grades

Plywood is made from a combination of veneer sheets glued together with the grain direction of the layers at right angles to one another. A combination of grades of veneers may be used. For example, an “A” grade may be used on the front and a “C” grade on the inner ply’s and on the back. The chart below shows the standard combination of veneers, which make up various grades for exterior type plywood panels, and shows which are recommended for the cow shaped step-stools.

Marine Grade - Marine plywood panels are manufactured with the same glue line durability requirements as other exterior type panels, but with more restrictive veneer quality and manufacturing requirements. Because marine plywood all use exterior glue and better grade veneers, they hold up exceptionally well outdoors. Common thicknesses are ¼”, 3/8” and ½”. Marine plywood is manufactured in the following grades, A-A, A-B and B-B.

Some producers offer panels with a pre-primed surface. When cutting parts for your cow shaped step-stool, only the sawed edges will need to be primed. Seal edges with one or two coats of top quality primer. MDO in 4-by 8-foot sheets or similar may be available from your local lumberyard or timber supplier. Call around to several lumber or building supply merchants.

#############################################
Plywood Panel grade designation, minimum Veneer Quality,
recommendation for the Face----Back----Inner Plies-----and suitability for making Wooden Step Stool Cows

Marine ply, A-A, A-B, B-B, HDO, MDO-Excellent

Special Exterior, A-A, A-B, B-B, HDO, MDO---Excellent

A-A----C----Excellent

A-B-A----B----C----Excellent

A-C-A----C----C----Good

B-B(concrete form)----Unsatisfactory

B-B----B----B----C----Usable

B-C----B----C----C----Usable

C-C Plugged-C Plugged-C-C-Unsatisfactory

C-C----C----C----C--------Unsatisfactory

A-A High Density Overlay-A-A-C Plugged, Not recommended

B-B High Density Overlay-B-B--C Plugged, Not recommended

B-B High Density Concrete Overlay-B-B-C Plugged, Unsatisfactory

#############################################
The above chart is based on information from the American Plywood Association (APA) and is shown only to illustrate the various types of plywood panels. For complete information contact the APA and request the booklet US Product Standard PS 1-83

The right stock, APA Sanded Plywood, Exterior-Type

Almost every lumber or building supply yard carries exterior-type plywood in A-C grade. This is generally the lowest cost exterior-type panel suitable for outdoor furniture. The “A” grade veneer used on the face of the panel is sanded and plugged. It is ready to prime. The “C” grade veneer used on the back of the panel will contain some open knots and/or splits which, if you are a proud wood crafter, will have to be filled. The inner layers of veneers are typically “C” grade. The open knotholes result in occasional open voids along the edges of the cut plywood. These voids will have to be filled before priming. A-C sanded plywood is widely used in a multitude of construction, industrial and do-it-yourself applications. These panels are made in a variety of thicknesses suitable for your wooden step stool cows project.

NOTE: APA ( American Plywood Association ) rated sheathing exposure 1, commonly called "CDX" is sometimes mistaken as an Exterior panel and used in applications for which it does not possess the required resistance to weather. "CDX" should only be used for Applications as outlined under Exposure 1 above. For sheathing grade panels that will be exposed permanently to the weather, specify APA Rated Sheathing Exterior. Exposure 1 Panels - Consists of a water-resistant bond and are designed for applications where long delays may be expected prior to providing protection, or where high moisture conditions may be encountered in service.

Preservative-Treated Plywood, not the right stock.

Plywood, which has been treated under pressure with the wood preservative Chromated Copper Arsenate or a similar, should not be used to make toys for children or items which can become toys for children such as the cow shaped step stools. If you have to use treated plywood, the EPA (Environmental Protection Agency) states that the following precautions should be taken:
1) Avoid skin contact. Wear gloves, a long sleeved shirt, and a dust mask when handling and cutting treated timber.
2) Dispose of sawdust and scrap wood in an appropriate manner. Never burn treated sawdust or scrap wood.

Imported Plywood – Finnish Birch, the right stock.

Finnish Birch is a very high quality plywood manufactured in Finland. It is ideal for outdoor furniture including wooden step stool cows, because it has very smooth surfaces, few if any interior voids, and it is made with waterproof glue.
The grade system used for Finnish birch is slightly different than with American plywood’s.
The grade sold by Meisel Hardware Specialties in USA is S/BB. The grading scale is as follows:

S Grade Veneer – Very high quality veneer. Generally no open defects. No patches allowed. (Similar to the American of Grade N)

BB Grade Veneer – Knots and open defects in BB face veneer have been patched with small oval or round plugs (patches) before gluing. I believe Geppetto had access to boxes and crates made of Finnish Birch Plywood grade BB some of which he used to build the house additions and a few wooden step stool animals including cow shaped ones.

Do not confuse Finnish Birch plywood with Baltic Birch plywood; the latter, whilst more readily available, is not made with waterproof glue. Not the right stock.

Sawing and Sanding Plywood- When sawing or sanding plywood, with a fret saw, jig saw, band saw, router or sander insure you have a good dust extraction system, as the dust thus generated might be a health hazard. Henry uses a canister type light industrial vacuum cleaner with the intake near the dust source. A normal household vacuum cleaner will do a similar job. Remember to empty the dust bag often, at least every hour of use, as the fine dust will block the filters very quickly.

How to Transport, Handle and Store Plywood

Unless you are buying off cuts or small size panels, you will have to deal with the standard size sheets of normally 4’ x 8’ (or 1200x2400mm).

Transport - Some merchant will deliver. Most merchants will load, or help you load the plywood panel onto your van, pick-up, utility, truck, roof rack or trailer.

Some preparation of your transport vehicle will be helpful, here are some hints:
Because the plywood panels mark and scratch easily, have some carpet carpet, old tablecloth, bed sheet or similar item to wrap around your panel for protection. If transporting the panel on a roof rack, wrap some padding around the rack and take it easy with speed, the plywood panels make a good wing and can fly away or break apart. A boat trailer can easily be improvised to transport large panels. If you have a van, but the panels do not fit between the wheel arches, add a temporary beam across the wheel arches to rest the panels on. Transporting the panels on edge will cause some damage. Protect your panels from weather exposure. Wet panels will stain and can deform. If all fails, plan ahead and pay the small fee to have the panels cut to a manageable, useful size suitable for your wooden step stool cow.

How to Handle the panels. - Unloading a full panel can be a challenge, it is best done with a helper. Always carry the panels in an upright position, short side vertical. Pay attention to the tops of doors and light fittings. With the cow shaped wooden step stool plans you will receive a very useful hint on how to acquire your cheap, one-man mobile combination worktable, unloading and panel-stacking device.

Storage of the right stock panels. - Ideally store the panels flat, resting on wooden supporting slats, in a dry and well vented environment. Unfortunately this will take some floor space, so the next best option is to store the plywood panels almost vertically, ideally in a frame, or simply resting against a wall in a dry and well-vented area.

Types of Paneling to Avoid, not the right stock

There are several materials which, although readily available, should be avoided. They have not been found to be satisfactory, they are too heavy, not robust enough, environmentally unfriendly or toxic to work with and to dispose of. Hardboard- Even the better quality “tempered” hardboard does not survive well outdoors. Particleboard- It has generally a smooth surfaces but is not robust enough, and does not survive outdoors. Wafer board- Some brands are made for outdoors, but these panels have too rough a surface Customwood- Some grades (high density) are waterproof, but very heavy. The sawdust from it is a known health hazard.

The right stock, Solid Wood, Cedar, Pine etc.
If you have access to cedar or similar good quality lightweight wood for your wooden cow shaped step stool, consider yourself very lucky and go for it.

Seconds, Rejects, Tester Panels and Recycled Plywood’s

Some merchants specialize in odd size panels, seconds, rejects and even recycled plywood.
The price is often attractive and for the handyman that just wants to make one, two or three cows, a sensible proposition. If you are going to paint your project, then surface finish of the panel becomes less important as it can be plugged and sanded to suit. Also, as there are almost no two real cows alike on this world, imperfections add to the final outcome.

Seconds and Reject Plywood Panels- Are panels that have manufacturing problems such as too many knots, sanding slips, ridges, fissures or delamination of the layers caused by the interruption of the glue supply, machinery breakdowns, operator mistakes etc. Often the fault is on a small section of the 4’ x 8’ panel and, because you require only a reasonably small part for your cow project, you can salvage a fair proportion of the panel. Inspect the panel carefully, test for “springiness” caused by large voids, and if you are satisfied and the price is right, take it. Henry has often been able to purchase perfectly good seconds, the only fault being an unusual, unique and often quite attractive grain pattern.

Testers Plywood Panels- When manufacturing panels, a series of tests have to be performed on randomly chosen panels. Consequently a corner of approximately 12 x 12 inches is cut off. The perfectly good panels, minus the corner, are usually sold as seconds. When making cow shaped coffee tables or larger items, Henry requires 1 inch thick plywood, full panels are expensive, heavy, and cumbersome to handle, a tester is cheap and can be cut at the merchant into two or three manageable panels.

Recycled plywood- If you have the time, the persistence, the transport and the knowledge, you can find good quality waterproof plywood from packaging. Check with warehouses, factories (machinery packaging), hospitals (medical equipment packaging), electricity suppliers (insulator packaging) etc. Often you can get the plywood packaging for free if you are willing to take it all (and thus solve their disposal problem). Always use gloves, safe clothing, safety goggles and good boots. Watch out for treated wood, lead based paints, chemical spills (battery packaging), asbestos and other banned materials, they are dangerous to your health, and the disposal of it might cost you considerable money.

Our Final Word on Plywood as the right stock

Always use the best quality plywood you can reasonably afford. Better grades of plywood, though initially more expensive to acquire, will save time, money and your effort because it will need less preparation. These plywood grades will also result in a longer lasting and better quality wooden step stool cow. If you can’t find any suitable quality plywood at your local lumber/timber yard, ask if they can do a special order for you.
Do not forget to experiment, it is just amazing what some of our friends have been using to make a unique cow shaped step stool.

We wish you a fantastic and successful time choosing the right stock and making your very own cow shaped wooden step stools.

An interesting update. Our artist, painter and decorator Paul is presently in India, near the Himalayas, looking for amongs a few other things, a source of rare and exotic wood stock for our unique cows and pets in wood. Click here to read Paul's interesting blog