After doing some research, I decided to make them from African mahogany (Sepele) and I machined the size of all the components a bit heavier (thicker) than the existing ones. The Festool domino joiner and Titebond III exterior wood glue would create a joint that would hold up well.
We had to do our glue-up in sections as there were too many joints to make before the glue’s set up time (15mins) so we first glued both of the sides (front leg, back leg, skirt and arm) …and did the same with the seats back …and clamped overnight.
sides and back rest
Next we brought the ends together with the back rest and two long skirt sections (front & back) and clamped again.
we attached ribs between the front to back skirts and screwed the seating slats to the ribs (from below) using deck screws (so they could be replaced if need be). Then we sanded a final time and soaked both seats in Watco Teak oil and applied a second coat the next day.
and with her cushions in place...
A yearly re-application of the teak oil will keep them as protected as is possible without having to sand off the entire old finish before refinishing (as would be the case with a marine varnish or other ‘surface coat’ finish). Now they can do their own maintenance (at each season’s end) before covering them for the winter. Russell Hudson / www.hudsoncabinetmaking.com
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