Restoring a 50-Year-Old Handmade Oak Bench

This project is a heartfelt restoration of a bench built by my grandfather over 50 years ago. The bench combines sturdy steel legs and 13 oak slats that had seen decades of weather and use. The wood was rough, moss-covered in places, and some slats were partially rotted or damaged. My goal was to bring the bench back to a solid, usable state while preserving as much original material and character as possible. Using common woodworking tools and materials like oak paneling from the hardware store, this guide shows a practical way to clean, repair, and protect outdoor wooden furniture — adaptable to your own restoration needs.

The tools and materials you’ll need may depend on your bench’s condition, your specific repairs, and what tools you have available.

Materials:

1. Wooden slats (original or new) and extra wood panels for repairs if needed
2. Wood dowels (to fill old screw holes)
3. Stainless steel screws (to replace old rusty ones)
4. Wood glue (weather-resistant)
5. UV-protective outdoor wood finish or oil

Tools:

1. Screwdriver or drill
2. Electric planer
3. Router
4. Table saw or handsaw
5. Orbital sander and sandpaper (various grits)
6. Steel wire brush
7. Clamps
8. Measuring tape and pencil
9. Paint roller or brush
10. Safety gear (gloves, dust mask, eye protection)

I began by removing the steel legs, then carefully took the bench apart by unscrewing the wooden slats from the frame. Some screws came out easily, but others were stuck or had stripped heads. In those cases, I either broke the screws out of the wood or drilled them out, depending on the situation.

Right from the start, it was clear many slats were damaged—some rotten, moss-covered, or full of holes. This initial inspection helped me decide which boards could be repaired, flipped, or needed full replacement.

I planed every slat on both sides with an electric planer to remove roughness and old finishes. While working, I carefully checked for any old screws or metal fragments embedded in the wood, since these can damage planer or router blades. For smoothing the rounded edges on top, I used a router fitted with a large bit that created a gentle curve.

Some of the screw holes showed larger dark spots where the wood had rotted and softened over time. I removed these decayed parts with a steel wire brush, clearing away all the soft, damaged wood that couldn’t be saved. Although these areas left visible dark marks, I found that they added character and a natural patina to the wood’s surface.

The backrest slats were mostly in good condition, while the seat slats had taken more abuse. I flipped many of them so their better side faced up. One slat was beyond saving, so I cut a solid oak board in half with the table saw to create two thinner boards. I then glued laminated oak paneling underneath these boards for added support, so they still look like the original slats from above but are much stronger (as shown in the images above). Others were partially repaired by cutting away damaged sections and gluing in new wood.

I used the table saw to trim the ends of each slat for a clean, even look—though a miter saw might be easier if you have one. All visible screw holes were filled with dowels, which I hammered in and then trimmed flush with a Japanese pull saw before sanding. When sanding, make sure to always wear a dust mask and safety glasses. I sanded the surfaces with an orbital sander and finished the edges by hand, working through progressively finer grits for a smooth touch.

Instead of the original dark stain, I wanted the oak’s natural beauty to show. I applied two coats of clear Osmo UV protection oil with a roller, letting it dry between coats. Once ready, I reattached the slats to the steel frame using new stainless steel Torx screws, arranging the thicker slats for the seat for extra strength. Finally, I bolted the steel legs back on, and the bench was ready for another few decades of use.

This restoration brought the bench back to full strength and durability. Anyone with basic woodworking tools can follow the same steps: remove damaged material, repair or replace parts as needed, and finish with a durable protective coating. This straightforward process helps preserve quality furniture and keep it out of the landfill, regardless of the tools or bench you have.