Background
My parents purchased a folding portable picnic table over 25 years ago. It was well used at their static caravan in the Scottish Borders and also while touring around the country. It is a very good example of good design where one structure folds out to provide a table surface and seating for four people. The two halves of the table surface also act as a housing which contains the seats and folding mechanism when the table has to be transported.
Over the years the plastic seats perished and split making sitting on them a little risky as any exposed skin could get very painfully pinched. Also one of the bolts securing one of the leg stays in place had dropped out and been lost. Other than that i thought the table could still be used with a little effort to replace the missing bolt and make new seat panels.
These folding portable picnic tables are still on sale today so the easy thing to do would be to dispose of this one and buy a new one but that hardly fits in with the 'Reduce,Reuse,Recycle' idea. I had some offcuts of 6mm marine plywood, spare stainless steel button head bolts and washers left over from other projects. All i had to buy were a packet of stainless steel M5 Nyloc (Nylon Locking)nuts costing just a few pounds and i have a few future projects where i can use the left over ones.
Over the years the plastic seats perished and split making sitting on them a little risky as any exposed skin could get very painfully pinched. Also one of the bolts securing one of the leg stays in place had dropped out and been lost. Other than that i thought the table could still be used with a little effort to replace the missing bolt and make new seat panels.
These folding portable picnic tables are still on sale today so the easy thing to do would be to dispose of this one and buy a new one but that hardly fits in with the 'Reduce,Reuse,Recycle' idea. I had some offcuts of 6mm marine plywood, spare stainless steel button head bolts and washers left over from other projects. All i had to buy were a packet of stainless steel M5 Nyloc (Nylon Locking)nuts costing just a few pounds and i have a few future projects where i can use the left over ones.
The first job was to remove the old plastic seat panels.
These were held in place with soft metal(Aluminum or zinc alloy) pop rivets.
The rivets were carefully drilled out and the holes in the frame cleared of any debris.
The hole in the middle of the table is intended for a sun shade or umbrella.
These were held in place with soft metal(Aluminum or zinc alloy) pop rivets.
The rivets were carefully drilled out and the holes in the frame cleared of any debris.
The hole in the middle of the table is intended for a sun shade or umbrella.
After the rivets were removed the cracked and damaged seats were temporarily taped and glued together so that they could be measured and used as templates for the new replacement wooden panels.
In this picture the folding seat stay can be seen in the top left corner hanging down on the ground due to a missing bolt and nut.
In this picture the folding seat stay can be seen in the top left corner hanging down on the ground due to a missing bolt and nut.
After removing the seat panel the rivet holes were checked for any damage and any debris from the rivets carefully removed.
The replacement seat panels were cut from 6mm marine plywood that had been left over from a previous project.
The original plastic seat panel was used as a template.
The holes were drilled and the new wooden panel was test fitted.
The entire mechanism was tested to ensure that it would fold down with the new wooden panels installed.
The original plastic seat panel was used as a template.
The holes were drilled and the new wooden panel was test fitted.
The entire mechanism was tested to ensure that it would fold down with the new wooden panels installed.
To ensure that the edges and corners did not catch on clothing and skin they were rounded using a palm sander and the entire surface was sanded to removed andy dirt or stains and to provide a good keyed surface for the varnish.
All the seat panels were secured in place and the mechanism tested to ensure all the panels fitted when the picnic table was folded for starage.
The new seat panels were removed a three coats of quick drying water based varnish were applied to all sides and edges.
The panels were sanded with a fine grade sandpaper to remove any grit or imperfections and washed before the final coat of varnish was applied.
After 4 hours dryinging the seat panels were reattached for the final time.
The panels were sanded with a fine grade sandpaper to remove any grit or imperfections and washed before the final coat of varnish was applied.
After 4 hours dryinging the seat panels were reattached for the final time.
The completed refurbished seats just waiting for a sunny day for their first day out!
The only expense incurred in getting the picnic table back into use was the M5 nyloc nuts. The other components, plywood, stain/varnish and M5 bolts were already to hand.
A few pounds, some surplus parts from other projetcs and a few hours work has brought this little table back to life, albeit being used slightly differently to the original intention but it was well worth the effort doing it rather than a trip to the tip!
The table can now be safely used by children or lightweight adults or as it recently was as a serving table with built in side tables...so much more convenient than trying to balance your drink on the grass.!
The only expense incurred in getting the picnic table back into use was the M5 nyloc nuts. The other components, plywood, stain/varnish and M5 bolts were already to hand.
A few pounds, some surplus parts from other projetcs and a few hours work has brought this little table back to life, albeit being used slightly differently to the original intention but it was well worth the effort doing it rather than a trip to the tip!
The table can now be safely used by children or lightweight adults or as it recently was as a serving table with built in side tables...so much more convenient than trying to balance your drink on the grass.!
This was the tables first outing at the end of August 2014. The sun umbrella base can be seen below the table, the umbrella was taken down so that the photograph could be taken.
The main table was used to serve food and drink and the seats used as side tables.
The main table was used to serve food and drink and the seats used as side tables.