Patio Chair Repair

[Don52]

My daughter has four chairs on her back concrete patio. The chairs have a 21” ring on the bottom of the pedestal as shown below. The rings on two of the chairs were badly rusted, so I decided to repair them.

1. Chair to be repaired


The other two of the four chairs look like they are brand new. I am not sure why this is the case, considering that they are all in what appears to be the same environment.

2. Top view of chair base


3. Bottom view of chair base


4. Rust on bottom 1


5. Rust on bottom 2

[Don52]

6. Rust on bottom ring


I decided to use a ring roller to manufacture the new ring. I decided to roll the ring from one piece of 7/8” diameter tubing with a .083” wall and a 21” ring OD. Notice that the idler rollers are in the furthest out position.

7. Me starting to roll ring


Notice that my friend John has the idler rollers moved closer by two positions. This is necessary to get the desired diameter of 21”.

8. Rolling the completed ring


9. Me cutting scrap from ends of ring


10. Me welding ring together

[Don52]

11. The completed ring weld


12. Weld ground and polished


Before rolling the ring for the second time we straightened out the ring.
(To make it planer)

13. Straightening ring


We decided to roll the ring a second time to help to make it rounder.

14. John finishing rolling the ring



15. Coping the chair legs

[Don52]

16. Welding one leg


17. Welding another leg


When I notched the foot, I left two flats to help me to hold the foot for the counter boring operation.

18. Notching foot


I left a scrap piece of 7/8” stock in the Jacobs Rubber Flex chuck as a stop for the foot that I was counter boring.

19. Drilling foot


20. Counter Boring foot

[Don52]

21. Two feet done


22. Painted and feet mounted


23. All done


-Don

[Metjunkie]

Don, reading your posts is like reading an article out of my Home Shop Machinist magazines. Great stuff, keep'em coming.

[ryanjones2150]

Undoubtedly far better constructed and quality control than the original Chinese manufacturing facility produced.

[Don52]

Don, reading your posts is like reading an article out of my Home Shop Machinist magazines. Great stuff, keep'em coming.

Thanks.

Undoubtedly far better constructed and quality control than the original Chinese manufacturing facility produced.

It is actually strange. The chairs were not particularly expensive, but were well made and heavy duty. The only problem is that the bottom of two of the four chairs rusted off. The seats of the chairs are also still in pristine condition. My daughter did have the patio hydraulically raised to make it slope away from the house instead of towards.it. Perhaps the two chairs that failed were in the deeper end of the puddle formed when the patio sloped towards the house.

-Don

[Don52]

My wife and I made a road trip to visit my daughter in Texas for Easter, so we brought the repaired chair bases along. I replaced the old rusty screws with new zinc plated screws to attach the chair bases to the seats.

24. Base mounted to seat.


And now the patio set is complete again.

25. Chairs back around table


-Don