Remaking a Leg




About: I like to get creative and use materials for their not intended purpose ! Working as a refinishing technician / painter dealing with high end cars ! Lots of fun spend 90% of my time outside and or tinkering ...

This Instructable shows how to remake a leg from a table or a vintage couch with silicon mold and fiberglass resin, possibilities are endless

The couch was bought with a broken leg with intentions to remake the leg to match the other front leg

This was all done at home in the driveway

Step 1: The Mold

I used a silicone 2 part 1 to 1 water based mix and mixed it up in a glass vase

put it on the leg in the glass vase propped with whatever i could find to meet my needs

let it set 12 min and then slipped off the mold

Cut the back into the silicon from the top of the leg and a bit of the bottom with a razor to carefully remove the mold from the leg then placed it bad into the vase to keep form

Step 2: Casting the Leg

I used bond brand Fiberglas resin from Canadian Tire. Its a 2 part mix with a catalyst hardener

Poured it into the glass vase with the silicon mold into it and let set

Then once hardend I removed the cast from the mold

and we have a replica of another leg

Step 3: Drilling

I drilled 3 inches into the resin cast leg and instead a threaded rod cut to the length I needed

Poured in some more resin in the negative space to make it stay in place

Did the same with the wood leg, drilled it out and used resin to hold it in place until the next step

Step 4: Filling in the Void

After all the resin has set up I used bondo brand short strand fiberglass mixed up and put in the space left from the wood leg to the cast

Used a plastic bag wrapped around the leg and the cast to make it more cylindrical as it sets up to make it easier to sand

Step 5: Carving and Sanding

I used a dremel with a diamond cutting disc to outline and make lines more deep

Then sanded with a 40 grit to shape it better

Having the cast on the bottom and the original broken leg on top made it easier to sand the lines in between

Step 6: Final Sanding and Paint

Finished my sanding and then painted it with a gold spray paint close to the original colour

Good to go

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    7 Discussions


    2 years ago

    TAKE YOUR SHOES OFF WHEN YOU'RE SITTING ON FURNITURE! HAHAHA Very nice instructable. Never thought of casting a broken leg. I usually go the long route, and remake the leg out of wood. Next time I break my leg, I may just amputate and recast the stump! ;-)


    3 years ago



    3 years ago

    awesome dude, love it!


    3 years ago

    Well that's one way and successful it seems .Why not make the leg longer and the join exact and avoid all the shaping? I suppose you cast from the back left leg so this will only work if all legs are the same which is not often the case that I have seen.

    1 reply

    Reply 3 years ago

    Oh I see now you cast the front left leg and turned it round so that's why you had to make it look right with carving .Looks good


    3 years ago

    Nice job, very cool way to save an antique from the trash.


    3 years ago

    Good job dude. Looks pretty good.