Nov 192 min read

Bring New Life to an Old Garden Bench – DIY Step-by-Step Restoration

When we moved into our new house a few years ago, the previous owner left an old garden bench in the backyard. It's falling apart, the metal is rusty, and some parts are missing. But instead of tossing it away, I saw potential for a makeover to bring it back to life.

Supplies

Tool list:

Step 1: Planning: Understanding the Structure

The bench is made up of two parts: the metal on the 2 sides and the main section, which consists of several pieces of lumber. I plan to keep the metal parts clean and restore them, as well as replace the panel sections with new lumber since the old ones are rotten.

Step 2: Disassembly: Taking Apart the Old Bench

Remove the nuts and bolts or screws if possible. In my case, the bolts and nuts were so rusty that I stripped the heads. With no other option, I had to use an angle grinder to cut through the nuts.

Step 3: Cleaning: Restoring the Parts

Use a metal brush and soap water to scrub the rust off the metal parts.
(optional) Use a power washer to thoroughly clean the parts.
Let it dry

Step 4: Painting: a Fresh Coat of Color

Apply a fresh coat using spray paint. Be sure to wear a mask to avoid inhaling fumes. To prevent overspray, either work in an outdoor area or use a box to contain the paint.

Step 5: Rebuilding the Main Body: Cutting the Lumber

I used 2x4 lumber for this project:

Cut it to the desired length.
Rip it to the desired width.
Rip it to the desired depth.

Next, test if the cut lumber fits between the two metal side pieces. If it doesn't fit, you may need to rip the lumber thinner.

I then used a trim router to round the sharp edges and an orbital sander to smooth the rough surfaces. Finally, I applied a coat of stain and sealer to the lumber, followed by an extra layer of polyurethane to ensure it's fully weatherproof.

Step 6: Assembly: Bringing It All Together

Assembling everything is relatively easy. Just use the appropriate size screws (or bolts & nuts) to fasten the lumber to the two metal parts, and you're done.