Park bench slats
I have gotten a lot of inquires from people wanting to buy replacement slats. If you would rather buy them instead of building your own, check out my friend Bryan: Atkins and Sons park bench slats. Anyone interested in building your own, please continue reading.
An old park bench
My parents have three park benches like this one pictured above. After 15 years or so, they have started falling apart. I made a set of replacement slats last year, for one of the benches, and I decided to make another two sets as a father’s day gift, this year.
Cutting 4′ lengths
I got a pile of 2-3/8″ white oak, hardwood flooring blanks from Alex at Vintage Lumber. They were perfectly straight, and just slightly larger than I needed. I cut the 8′ long pieces down to 4′ long and ripped them down till they were about 1/16″ over sized.
Ripping down to size
Jointing the edges
I stacked them together and ran them through the planer, on edge, about six at a time. This jointed them down to size.
Planing down to size
Next, I rolled them onto their faces to plane them down to the desired dimension in the other direction.
Stock all dimensioned
Drilling jig
The last time I made these, I built a simple jig that I could clamp to my drill press. It allowed me to hold each slat centered under the drill at my desired dimension from the edge.
Setting up the wider stock
Follow up with a forstner bit
After I drilled the through hole on both ends of each board, I created a counter-bore with a 1/2″ forstner bit, set to drill down about 3/16″ so the screw head will be below the surface of the seat.
Counter-bored hole
Drilling the narrower pieces
These benches have nine 2-1/8″ slats and three 1-3/8″ slats. The smaller ones go into the inside curve at the back of the bench. I made my jig wide enough that I could add a spot for the narrower boards as well. I quickly repeated the drilling process on the smaller boards as well.
All the boards drilled
Quarter round each edge
With all the drilling done, I wanted to smooth over the corners. The original bench had a small radius on each corner so the slat didn’t have any sharp edges. I put a 3/8″ radius on my slats. I like the bigger radius. It seems to do a better job of avoiding splintering. I set the round-over bit up in my router table, and set the feather boards. I ran all four of the long sides through. there was no need to do the short sides. I want more strength near the screw holes.
All the edges rounded
When all the edges were rounded, I set up my buff sander in my drill press, and ran through any boards that needed any additional smoothing. I will leave it up to my dad to select a finish, I much prefer doing the grunt work instead…
Buff sanding
Midnight Woodworking 
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I need a set…would u make them. If so at what price?
I need 36 park bench slats. What would be the cost? Do you make them?
I put a link in the first paragraph, of this post to my buddy Bryan’s business. He makes them and can help you out.
http://bryan-atkins-hjih.squarespace.com/
I have a park bench that I’m trying to turn into a storage bench not sure how can u help with ideas
Would you consider making us a set? If so, how much would you charge? If interested, I can send measurements and how many slats we need. We already have the replacement nuts and bolts. We just had the iron part of the bench powder coated. Thanks.
Very nice. Thanks for the tutorial. I found that a good source of lumber can also come in the form of an old church pew. I found a 10′ white oak church pew on Craigslist for $20. The lumber has been indoors for decades and it cut nice and straight. I just need to round the edges and coat it with marine-grade protective finish before assembling everything.
Fantastic, I am glad this post was useful to you.
Okay. Did you make your “buffsanding” attachment ?
No, I picked that one up from Peachtree at the woodworking show.
Where might I purchase/order these?
I put a link in the first paragraph, of this post to my buddy Bryan’s business. He makes them and can help you out.
http://bryan-atkins-hjih.squarespace.com/
Thanks but no good to me in Scotia
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I just rescued a bench that was to be picked up by waist management in the morning. the 5 slats for the seat are completely rotten, but the iron is in great shape. I could send you a picture if you respond by email. It just seems sad to destroy the good with the bad. I look forward to hearing from you.
Absolutely you can restore it. All you need to do is replace the few rotten slats with some made from weather resistant wood.
Thanks, I’ll try Home Depot unless you have a better idea for me 🙂
I live in Palm Beach County, Florida
I am not familiar with the area. White oak is probably the least expensive option. Mahogany, ipe, or other rot resistant hardwood. Not pressure treated wood, it would not be strong enough. Good luck.
Thanks! I will be going to Home Depot today!
I have two bench ends but I am missing the brace across the back as well as the horizontal bar across the bottom. Any idea where I can get those? White Oak seems like a strong wood does it effect the stability if I do not have those pieces?
Typically there is only one thin strap of metal running along the center, connecting all the slats together to prevent spreading. You could buy a thin strip of steel or aluminum and drill a hole to place a screw into the center of each slat, and it would do the same thing. I haven’t seen one with a horizontal brace across the bottom. The slats should be stiff enough without a brace. Your stability should be fine without the braces, but without the center strap, your boards may want to spread a bit over time.
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I have the metal ends of a bench. If I make the bench 51 to 56″ wide, how thick should the slats be? I was thinking of using cedar as white oak is pretty expensive.
I would think 3/4″ thick to 7/8″ minimum. Possibly even 1″.
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Good morning. Where did you get your buff sander attachment for your drill?
I picked mine up at a woodworking show originally. Klingspor sells them as “Klingspor Abrasives Gold Sand Mop”. Several other companies also sell them as sanding mops.
Have any ideas who might have curved decorative pieces for the back portion of the cast iron benches?
Steve Lavin
Jan.11, 2021
The only person I know of is probably my buddy Brian. Yours is website you can contact him and ask.
https://bryan-atkins-hjih.squarespace.com/