How to Refinish Vintage Metal Furniture: Wire Wheels vs. Sandblasting
Refinishing old metal patio furniture can breathe new life into pieces that have been sitting unused for decades. While sandblasting is often the go-to method, it can be too harsh on certain materials, potentially causing irreversible damage. In this guide, we walk through a DIY approach to restoring a beautiful 1980s custom metal patio furniture set using alternative tools and techniques.
Tools and Materials Needed
Drill Attachments:
- Best Wire Wire Wheels for metal furniture restoration (3-inch & 2-inch) (2 Inch- Home Hardware, 3 Inch- Home Hardware)
- Paint Stripping Wheels- Home Hardware
- Metal Sandpaper (80 Grit)- Home Hardware
- Corded Drill- Canadian Tire
- Cleaning & Preparation:
- Zep Degreaser- Zep
- Heat Gun- Home Hardware or Propane Torch - Home Hardware
- Coca-Cola- Sobey's (optional for removing rust from nuts, bolts, and fittings)
- Safety Gear:
- Respirator- Home Depot
- Safety Glasses- Home Depot
- Drop Sheets- 3M(optional for dust control)
- Shop Vac- Stanley Tools (for cleanup)
- Hat, Long-Sleeve Shirt, and Long Pants- Mark's (optional, but recommended for dust protection)
Removing Rust and Old Paint
Before tackling the main furniture pieces, I experimented with Coca-Cola as a rust remover for the nuts, bolts, bearings, and fittings. I'm considering an addition to Sydney's Journal about this one, for now, let's focus on our DIY patio refinishing guide on how to strip old paint and rust from metal. I let them soak for a few days at room temperature, and to my surprise, it worked! A bit of wiping and wire brushing removed even the heaviest rust. While not necessary, this step allowed me to salvage more of the original hardware. There are some tips and tricks, also warnings to look for as we do not want to release any dangerous chemicals, as always, do your research before using any type of chemicals, liquids, tools, etc, in your projects.
For personal protection, I wore long sleeves and changed clothes outside after working, ensuring that any lingering chemicals or dust didn’t affect my wife or pets. All work was done outdoors in a well-ventilated area. Before diving into the main project, I tested different rust removal techniques on smaller parts.
The Story Behind the Restoration
A client in Oakville, Ontario, reached out after reading my blogs. They were thrilled to find that a local Canadian artist offered furniture refinishing services. Their project? A vintage four-piece metal patio set that had been sitting in a dark, cold shipping container at a golf driving range since the 1980s.
The original owner had attempted to restore these chairs in the 90s using a grinder and wire brush attachments. However, the process proved labor-intensive, and the project was postponed. When we unearthed the pieces—including bases, backs, and an elusive box of hardware—it was clear that this was going to be a meticulous job requiring some determination and an alternative to sandblasting metal furniture.
Pricing the Refinishing Work
After evaluating the chairs, we agreed on a price that included materials, labor, powder coating, delivery, and assembly. Since every metal surface was rounded, removing old paint and rust from the intricate curves of the armrests and frame was going to be challenging. Looking back, I wonder if including free buckets of golf balls for life would have been a more lucrative approach and a unique gift idea. I suppose a dream is a dream. That said, I will be going back come springtime.
The Refinishing Process
Step 1: Securing and Heating the Surface
To prevent movement while working, I secured the chairs to my workbench using clamps. Then, using a propane torch, I heated the surface to loosen old paint and powder coating. The key here was to avoid overheating the aluminum, as it can become malleable and risk cracking at the welds.
Step 2: Choosing the Right Wire Wheels
With the surface warmed, I tested different wire wheels for efficiency:
🛠️ 2-inch wire wheels: Effective for reaching tight crevices but wore down quickly.
🛠️ 3-inch wire wheels: Best for overall removal, especially when using the drill in reverse for better surface tension.
🛠️ Paint stripping wheels: Great for flat areas and eventually conforms to curved surfaces. This was the main disk for the job.
After experimenting, I found that a combination of heat and sanding disks worked best, with additional sanding by hand for difficult-to-reach areas.
Step 3: Sanding and Finishing
Once most of the paint and rust were removed, I switched to sanding disks. These disks adapted to the curved surfaces, making it easier to achieve a smooth finish. Any remaining stubborn spots were handled manually with 80-grit sandpaper.
Throughout the process, I frequently reminded myself to use heat, which significantly cut down on labor time and made stripping the metal much easier.
Step 4: Nuts and Bolts
That's right, when I said sustainability, we're going all the way down to the nuts, bolts, and bearings. Every piece of this vintage set, including the fasteners, will be original.
Cleaning and Prepping for Powder Coating
✔️ Step 1: Wash chairs with water & dish detergent to remove dust and debris.
✔️ Step 2: Apply Zep Degreaser for a deep clean.
✔️ Step 3 (Optional): If space is limited, a bathtub/shower can be a convenient alternative!
Powder Coating: The Final Touch
For the powder coating process, I worked with Bristol Powder Coating at The Metal Finishing Center, a local metal finishing company. The team, shout out to Jeremy and Penny, made the entire experience seamless. After selecting RAL9003 Signal White, I expected a wait time, but they completed the job in record time.
One thing that stood out was their attention to detail. Despite powder coating being an industrial-strength finish, they still wrapped the chairs in protective foam and plastic for transport—an extra step that showed their commitment to quality. Also, the staff was noticeably competent, kind, and friendly, which always leads me to believe that they are well managed. Special shout out to Jeremy and Penny for their assistance, if any executives are reading this, give these folks a raise, staff too! And again, no, I am not affiliated with them in any way.
Seat and Backrest Materials
With the refinishing process complete, choosing materials for the seats and backrests was the only thing left. Some possible options include:
✅ Seat & Backrest Material Options:
- 3-inch wooden planks – Stained and curved for comfort
- Vinyl strapping – Flexible and weather-resistant
- Rope or leather accents – Adds a decorative touch
- Plastic bases – Durable and easy to maintain
I will be updating the blog once the final materials are selected and installed!
The Reward of Restoration
This project was time-consuming, messy, and required serious attention to safety. Wire wheels, for example, can be dangerous—if they catch onto clothing, they can spin uncontrollably. Proper technique and caution were essential.
But seeing the transformation from rust-covered chairs to beautifully restored patio furniture made every hour of labor worth it. The before-and-after images truly highlight why this labor of love was so rewarding.
⚠️ Restoration Safety Tips:
- Wear protective clothing – Long sleeves, gloves, and safety glasses
- Secure loose clothing – Wire wheels can catch and spin out of control
- Work in a ventilated area – Avoid inhaling dust and chemical fumes
- Use clamps for stability – Prevents the piece from moving while working
- In Closing
At Sydney’s Collection, sustainability is a core value. If an item can be restored instead of replaced, we always encourage that option. Not only does it preserve unique gifts and decor, but it also prevents unnecessary waste.
If you’re in Oakville, Mississauga, Toronto, Burlington, or Hamilton, Ontario, and need metal patio furniture refinishing, reach out to us, you can contact us here by email or on our contact information page. We also have artists available for refinishing services in the following cities:
Canada:
- British Columbia
- Calgary
- Halifax
- Ottawa
United States:
- Chicago
- San Diego
- New Jersey
- Seattle
Australia:
- Sydney
- Canberra
- Adelaide
Ireland:
- Greater Dublin Region
United Kingdom:
- Cambridge
- Bristol
- Liverpool
Need your patio furniture restored? Contact us today for sustainable refinishing services in Canada, the U.S., the U.K., and Australia!
Please note that I am not affiliated with any of the provided links other than the internal Sydney's Collection page links like contact, blogs, and home page. I do not get paid for any links or sales at those links.
