Cast Iron Bench Restoration with Wood Slats

Here's my latest cast iron bench restoration project where I prep and repaint the rusty iron framework and replace the wooden slats on two garden benches. You can also follow my how to restore cast iron garden furniture video for a helping hand.

Something my Dad keeps telling me is to look for a rusty old cast iron garden bench with wooden slats around car boots. Apparently, many won't or don't know how to restore cast iron garden furniture.

What's your time worth? And can you source the materials cheap enough?

Anyway, in short, my Dad found two. One was for his customer which just needed some updating, the 2nd was in my brother's back garden where the wooden slats were completely rotten.

Let me talk you through how I did it and what tools you can use and how long it should expect to take.

Tools I Used (+ Suggested Alternatives)

• Wooden slats - I used oak planks that I ripped down *(see note 1)
• Table saw* (see note 2) and a chop saw
• angle grinder *(see note 3)
• Screwdriver
• Spanners for removing bolts
• Safety gloves
• Ear defenders
• Safety glasses/goggles
• Wood preserver - note some wood stains don't offer protection!
• Wire brush *(see note 4)
• Direct to rust metal spray paint *(see note 5)

Note 1 - Alternative Woods

Alternatively, you could try a softwood, like pallet wood if you can source them long enough. BUT, it'll require lots of treating and won't be as strong as a hardwood.

Note 2 - Table Saw Substitute

It's only the last few months I've been using a table saw. If you don't have one, you could:

• Clamp the wood to a workbench and jigsaw, then sand straight
• Hand saw, although it's harder with hardwoods
• Rip down timber with a bandsaw - my favourite method these days where possible
• Use a track on a circulaw saw or cut with a clamped straight edge

Note 3 - Angle Grinder Alternative

I know angle grinders can be quite intimidating to remove the bolts. Especially the sparks, so it's vital you wear PPE. However, you could:

• Use WD40 penetrant and leave it to work overnight before unbolting
• Cut with a hack saw - but you'll need LOTS of time and patience!

Note 4 - Wire Brush Substitute

If you want to speed up the job, then I'd highly recommend checking my rusty metal gate restoration on how I used gifted Abracs poly abrasive discs in my angle grinder.

Or, you might love the Worx MakerX mini angle grinder with sanding disks which I used in the same metal gate restoration on intricate detail. BUT, how much rust you need to remove depending on note 5:

Note 5 - Other Paints

If you want to do this job in a day, then I personally would favour a spray paint as opposed to applying metal paint with a brush. It's easy to build up the coats and quicker drying on a nice day.

ALSO, I recommend using direct to rust paint that is a primer and paint in one.

How to Restore an Iron and Wood Bench

First and foremost, you'll need to remove the hardware. This may sound easy, but if your cast iron wood bench restoration starts with it being in poor condition, the screws and bolts may be rusty and seized up.

With some planning, you can spray the bolts with WD-40 penetrant the night before to work into the rust and repeat on stubborn ones. You'll also need spanners or anything to grip the nuts while unscrewing bolts.

BUT, don't destroy the wood in the process as you'll benefit from using them as a template for drilling bolt holes later.

Removing Rust (And How Much You'll Need To)

When restoring a bench with rusty cast iron, my tip is to think first regarding the type of metal paint you're planning on using.

As tempting as it is to strip back to bare metal, for quickness, you can use a direct to rust metal paint without the need for primer. In this instance, using a wire brush to flaky rust and paint would be ok.

If you're opting for primer and paint, you'll need to take back to bare metal. In this case, the best way to get the rust off cast iron in my opinion is using abrasive disks in an angle grinder. You'll save yourself hours of time.

Now clean it a good clean and leave to dry.

Replacing the Wood on a Cast Iron Garden Bench Seat

The type of wood you choose will make a huge difference in how long it lasts. You could opt for softwoods and even pallet wood, but it won't be as strong and will require regular treating while out in the elements.

Where possible, try to opt for hardwood which is more resistant to water and rot. If you can't find any timber at a local woodyard or DIY store, consider checking out affordable replacement bench slats.

Or even rip down an old oak coffee table, etc that you might have found at a local charity shop, jumble sale, or skip.

Cutting Bench Slats

Above, I ripped down some oak planks on my Dad's table saw all to the same depth as the original planks. Note, some will vary around the curved areas or near backrests that have cast-iron detail.

As for the back rest, my oak slats were slightly shorter than the original. This didn't matter for the bum area, but it did to mount around the cast iron back.

I had to line it up with the start of the floral cast iron section to see how much it protruded. Then divided it by half to determine the thickness. This also needed cutting down to the right length.

See note 2 above in bold regarding substitutes for a table saw.

Adding a Profile Edge to Your Bench Slats

To give your cast iron bench with wood slats a more professional look, I recommend using a palm router (or router table) to take the boxy edge off using a curved bit.

This will reduce the chances of splinters and be more comfortable to sit on.

Alternatively, you could hand sand the sharp edges while sitting, which admittedly, can be a great time to rest your knees(!)

Treating Your Iron and Wood Garden Bench

While you have easy access to the end grains (the thirsty bit of wood), I highly recommend to take the time now, to treat your bench slats.

I always favour Ronseal's Total Wood Preserver in clear as it's good quality and if I splash some on the cast iron's paintwork, it won't stain.

Pro Carpenter's Tip

Avoid products that simply don't say preservative or preserver on the label. My Dad informs while staining my fence panels it's just coloured water. Also, once stained, you'll need to keep it up when it fades.

Painting Cast Iron Bench Ends

For my next refurbish cast iron bench step, I painted a couple of thin coats of direct to rust metal spray paint the seat's frame. This allowed it to dry quickly and less waiting time between coats.

Alternatively, you could apply metal paint with a brush that is more hardwearing. But, it's thicker and takes longer to dry.

However, I think regular cans of paint are cheaper to use, reduces waste and are less harmful on your lungs and environment.

Drilling Holes for Wrought Iron Bench Wood Slats

Now, remember when I said keep hold of the old wood? Well, now you need to line them up with your newly cut ones and mark where the bolt holes are.

My oak bench slats were shorter, so I needed to line up one end, then line up the other.

I recommend drilling with a small drill bit first for better accuracy, then move on to a bigger one.

Building the Garden Bench with Cast Iron Ends

This can be quite the juggling act if you're rebuilding your newly restored garden bench! I recommend pushing one end against a wall so you can slot and bolt your first wooden bench slat in so it's stable with the rest.

As for the backrest, I then predrilled and screwed the cast iron backrest to all my previously cut framed pieces.

BUT, if yours is ALL wooden bench slats, then slot them all in first after the initial one and THEN bolt it all up. If not, you'll struggle to get the last few in on an angle and will need to unbolt some.

Making Your Park Bench More Stable

The final steps you need to take are to add bench supports which stabilise the slats and prevent them from sagging.

I bolted one on either cast iron bench end and screwed the opposite side in the middle.

Then a middle strip, which I predrilled and screwed to the slats.

How to Restore a Wooden Bench

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