After 10 years of service, our outdoor setting has started to fall apart. This has been my first opportunity to do some home repairs using hand tools.
I have an outdoor setting that has come with me from house to house for the last 8 years that I purchased second hand. My goal with this project was to demonstrate that, cheap wood furniture can be upcycled by repairing the weak links with traditional techniques.
With a hand full of hand tools and a bit of time, we were able to save ourselves the cost of a new outdoor setting.
- Hand Brace
First stage was to disassemble the chair and remove the broken part. The broken component is essential as it is used to mark up the duplicate. Next I purchased the closest size DAR timber from a local hardware store. I rough cut the timber to length using the hand saw and used a marking gauge to mark out the correct dimensions based on the original and marked to size.
Using the Jack plane, I dimensioned the timber to the gauge lines and had my material ready for structural operations. I also aligned the broken piece and the prepared material next to each other so I could mark the locations of each operation with a pencil and square.
Using a 16mm and 10 mm auger bit, and a brace was able to make the counterbore hole for the chair bolt. Using a 1/4 inch chisel and the mallet, I could start to cut out the mortise. The technique I followed for the mortise part can be found here.
Repeating this technique, I was able to replicate the old part with square holes instead of round ones.
Then, using a saw I cut the angle at the bottom, and fit it to the chair back.
This was a great little project. It only took me a few hours, and the tools required to complete the task can be purchased for a pittance. We were able to up cycle our cheap old outdoor setting and extend its life for another few years.
More importantly, I got to learn some great new skills and have the satisfaction of repairing an item using my hands.
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