Garden Bench Refurb
Intro: Garden Bench Refurb
This project started when I was talking with my landlord about a bench he has at his other property. It was rusty and rotten but I could see the potential. He ended up letting me have it for free because it wasn't safe to use and a bit of an eye sore.
I had to remove one side to get it into my car. But here is what I started with.
Everything was disassembled and measured.
I don't have every tool I should have used but I made due
The tools I used for this job:
Table saw
Cordless drill
Table router
Orbital sander
Miter saw
Materials:
2 x 1x6x8' cedar boards
Marine quality Spar varnish
Black matte spray paint
Nuts and bolts and screws
STEP 1: Cutting
I ripped all the boards down to be 2.5" in width. Leaving me with 8 identical pieces of cedar. But the side parts along the back are only 2" so I took my 8th board and ripped off another 1/2 inch which I took back to the miter saw and cut down to size of the original sides plus 1/2" extra on both sides because I decided I was going to create a rabbet joint for increased stability because the only thing holding the original sides on was screws ( the bolts are in the top and bottom board)
STEP 2: Sanding 1
STEP 3: Routing
4 of the bench boards were routed with a 1/4" bit to round over the top edges
The last board which is to be the front board of the benched received a 1/4" round over and the other received a 1/2". To make it more comfortable.
For the back I only rounded over one edge with a 1/2" bit. The rest remained square.
I then created my rabbet joints to connect the top and bottom. This was done with a 3/8" bit to cut the slot and I used the fence to trim down the access on side pieces to fit.
STEP 4: Dry Fit
I wanted to get an idea of what the final product would look like before is started the finishing stages and I'm glad I did. I hadn't noticed that the back iron was not square and had access iron in some spots so used my router to shave 1/8" off the bottom 2/3 of the inside edges of each of the back boards. I also use my wood chisel to fit the iron snug where there was that access iron. Then I finished the dry fit and was happy.
STEP 5: Drilling & Sanding
I used the old boards as a template and drilled all 14 holes with a 1/4" bit
Then I sanded and sanded and sanded with first 120 grit then 220 grit what flat edges I could with the same set up I did with the 80 grit for the routed edges I sanded them by hand. I wiped them all down with a dry rag to get any residual dust off
STEP 6: Wash, Paint and Varnish
I tested the finish out on a piece of scrap from the board I used to create the side pieces. After I let it dry over night and was satisfied with the finish I started my first coat
As I let the first coat dry I finally turned my attention to the iron. I sprayed down the iron with a vinegar water and dish soap concoction I found online and started scrubbing with a fine brillow pad. The rust wasn't as bad as I thought so after an hour or so I had nice clean cast iron and fixtures.
I followed the instructions on the varnish to apply the second coat.
The next day I sanded the wood to apply a third coat and spray painted the iron and fixtures now that they were dry.
I ended up doing four coats mostly because I ran out of time and the humidity was so high it needed more time to dry.
10 Comments
TheOriginalNerd 7 years ago
Thank for posting this. A neighbor was about to throw out a bench very similar to yours because the boards were old, warped and cracking. I mentioned it could be fixed so they gave it to me and now I've found this instructable that can help me with doing it.
buck2217 8 years ago
Lovely job
skapich 9 years ago
I have this same project to do. Thanks for posting.
ajohnson145 9 years ago
no problem! Post yours when you're done
zamzamj 9 years ago
nicely done :-)!
lilchumy 9 years ago
Scumm7 9 years ago
Gorgeous bench. I have one with cast iron fiberglass that is peeling. I've been pondering how to save it for awhile. I was thinking I'd sand/paint it, but I know that'd just wear out again over the season. Wood replacement would work great..
ajohnson145 9 years ago
Thank you! The great thing about the Cedar is if you want it really low maintenance. You can just let it go natural and it will last for years if you don't mind it turning gray.
Ysabeau 9 years ago
The before-after is amazing! You did a great job.
ajohnson145 9 years ago
Thank you! It was a great first project to get back into woodworking again after many years away.