Deck Chair Rebuild

br549 · Post by **br549** » Sat Dec 07, 2019 10:28 am

My sister had 4 white oak deck chairs that needed refinishing and new hardware. I was surprised that non-stainless steel hardware was even used in the first place, and by the time I got the chairs, the rust was pretty severe.

Using a Harbor Freight Plug Cutter, I used the smallest size I could, with a guide block to help guide my handheld drill, cut around the rusted screws and bolts to allow removal with vice-grip pliers.

Holes were then re-bored slightly larger with Shopsmith, speed reducer, and Forstner bits, and new plugs cut with Fuller brand plug cutters.

Stripped old finish, sanded mostly by hand, stained and applied Spar Varnish. The dark stain helped hide areas of discoloration that couldn't be sanded away.

Rope seats were cleaned with bleach and re-installed.