Restoring a park bench

[Simpo Two]

I've volunteered to restore an 8' long Victorian-style park bench (installed in 1977 and been outside ever since) and have got myself a little stuck.

It comprises three quite fancy metal brackets (poss cast iron) and 7 planks of wood which are bolted onto the brackets with bolts about 1/4" thick.

1) Despite removing the nuts (some just sheared), the bolts won't tap or even hammer out. Don't want to get too violent in case the brackets break. I can't believe the brackets are threaded so guess the bolts are just rusted in. Any way to remove them? Drilling them out is beyond my facilities and I want to re-use the wood so total destruction is not an option.

2) When I get the planks off the brackets, I'd like to strip and repaint the brackets. Would this be done best with a wire brush in a drill/angle grinder, or dipped in something noxious?

[sjj84]

Any pics so we can see what you mean?

What about soda blasting? No idea if it'd work, I'm intending on trying it on a garden bench when i get the chance.

[It's fixable...]

Since the bolts are only 1/4" / M6 size is it not possible to centre punch the bolt heads and drill out from that direction?

Assuming there is sufficient meat in the brackets and wooden slats the fixings could be upped to M8 size after drilling out to account for any "destruction".

Replace the existing fixings with A2 or A4 stainless fixings from a chandlers to leave an easier job for the next restorer!

Depending on how rusted the brackets are, i'd get them grit blasted, try Airblast at Gosfield, which I think is not too far from you...

Assuming there is funding available, have them blasted back to white metal and shot with holding primer before you collect.

Otherwise for minimum cost, rotary wire wheel will work almost as well, but might not get the worst / deepest rust.

[Simpo Two]

Here we go - best shots I could get in a rather full garage with bright sunlight...










Some of the bolts are bent - perhaps deliberately bashed over as an anti-vandal idea?

[P924]

Can you lock a couple of nuts to the visible thread, then use a spanner to break the rust?

or penetrating fluid / heat cycle etc.

[stewjohnst]

You can make short work of the bolts with an angle grinder and then replace.

I’ve tended to do that resorting mine as it just saves a world of faffing about.

[Jonesy23]

Or use something like oxalic to dissolve the rust? Won't hurt the wood though you'd have to give it a good rinse afterwards.

You'd have to work out a way to soak the centre section but each end would only need a shallow container.

[Simpo Two]

P924 said:

Can you lock a couple of nuts to the visible thread, then use a spanner to break the rust?

or penetrating fluid / heat cycle etc.

Two of the bolts have sheared already so I don't think the double-nut idea would work, but worth a go I suppose, especially with more WD40. Can't use heat due to proximity of the wood.

stewjohnst said:

You can make short work of the bolts with an angle grinder and then replace.

The problem is that they seem rusted into the frame. Even where the bolt ends sheared off, they show no signs of moving with a hammer and too much force will break something.

The nuts holding the front plank on are too close to the frame even to get a socket on them.


This is why I stick to woodwork!

ETA Worst case scenario is that I cut the ends off - it will give me a shorter bench but I can then use extreme violence to get the bolts out. That just leaves the middle frame...

Edited by Simpo Two on Tuesday 3rd July 11:10

[anonymous-user]

Looks like they have rusted solid, I hink the only way you will get them off is to cut them off and use brute force. Considering one of the planks is split anyway, would it not make more sense just to replace them anyway?

1)Cut the bolts off
2)smash off the planks
3)Get the metal frames shot blasted.
4)Paint
5)New wood and bolts.

[P924]

I guess you'll have to drill the head off the bolts, to release the wood, then either work them out, or drill straight through. Have you got a drill press?

[crankedup]

WD40 is a waste of time, for a proper penetrating fluid Plus Gas is the one to use, brilliant stuff.

[2Btoo]

Why do you want to re-use the wood? It looks quite old and split to me.

I'd go with the suggestions of sacrificing the wood, being heavier with the bolts and replacing the slats with some nice hardwood. It'll look proper nice that way.

[Fatboy]

I would try welding a nut (M10 or M12 should be about the right size) to the top of each bolt (the domed head of the carraige bolt) and get a socket on that to try and turn the bolts and free them up (looks like they're just held into the frame by rust & gunk)...

Failing that if you can get an inductive heater on the bolts that might free them up without putting too much heat into the wood (it'll char round the bolt holes, but probably won't burn...)

[steveo3002]

tap em through , support the casting and go carefull , once the head is proud get some vice grips on and wiggle em

[FlipFlopGriff]

Could you try a hacksaw blade to try and release the rusted surface or cut off the nut (just be careful), otherwise just persevere with the release fluids as you don't want to break the cast iron. I've done a few benches and used oak slats and stainless fixings. I wouldn't blast it as you'll lose the patina (you only get that once), just get the studs out, new slats and studs and use it. I've got a couple of really old bench ends recently which just need a big slab of wood on the base and the back, ie not slats. Picked up a few knackered slat benches for less than £15 each - look good dotted around the garden.
FFG

[FlipFlopGriff]

Something like these to replace the bolts:
https://www.ebay.co.uk/itm/Carriage-Bolts-A2-Stain...
Looks like you need a decent length.
FFG

[boyse7en]

2Btoo said:

Why do you want to re-use the wood? It looks quite old and split to me.

Presumably because he is doing this as a charitable work/volunteer work and has a non-existent budget for materials.

New wood will have to come out of his pocket i suspect.

[Jonesy23]

OK.

So first job if the bolts really are frozen in is to get the slats off. Ideally by drilling the heads off as at least that gives you a stub to work with.

Then deal with the bolts afterwards - freeze spray, penetrative fluid, rust removing (not converting!) solution, tighten a nut down the thread to try to pull the thing through, valve spring compressor, wiper puller, all sorts of options.

[Simpo Two]

Wow, lots of ideas there, thanks all. Budget isn't an issue, I'd just like to keep as much of the wood as possible as this bench has a sentimental attachment.

No welding gear or pullers here unfortunately; I'm not tooled up for metalwork. I have a drill press but it would be impossible to use because the frame's in the way. Some 1mm metal-cutting disks for the angle grinder are on the way so cutting off excess bolts will be simple enough, it's then just finding a way to get the bolts out. Still, it's a good retirement project!

[anonymous-user]

I'd say dip and powder coat the brackets, new wood, new stainless coach-bolts as a minimum if you want it to last another 20+ years. It's not the most sentimental way, but it will be the hardest-wearing.