Sun and weather take a toll on outdoor furniture. I had four outdoor bar stools covered with plastic resin wicker that had cracked and split. I priced new outdoor bar stools, ($75 and up x 4.) I figured I could renovate my old stools for about the price a single new chair. The plastic wicker had to go, but the powder-coated steel frames still looked good. I repurposed an old whiskey/wine half-barrel to provide all the material for the seats, backs and bracing. If you are even a little bit handy, possess basic wood working skills, and have some ordinary tools, you can knock this out over a couple of weekends. I wound up with great looking and very serviceable barstools from a single half-barrel and a hand-full of screws.
Step 1: Remove Resin Plastic Wicker
You can see how the plastic had cracked and split. I cut away the plastic wicker from the barstool frames using a utility knife; taking care not to scratch the powder coating.
Step 2: Materials List
• 1-Oak Half Barrel w/ Hoops
• Barstool frames (up to 4)
• Zink Coated Phillips Screws (per barstool)
14 - #10 x 1-1/2” Oval Head
8 - #10 x 1-1/4” Pan Head
9 - #12 x 5/8” Pan Head
• 1 qt. 'Spar' exterior polyurethane - oil based
• 1/2 pt. Wood Stain - oil based
• Sandpaper - Belts (80 grit)
• Sandpaper - Sheets (120 & 220 grit)
* 1 pt. Rust Remover (for barrel hoops)
* 1 qt. Wood Bleach (oxalic acid)