Building a rustic bistro patio set is a great way to design them the way you want, without having to spend a ton of money. It is a very easy task if you know how to weld, form metal, and paint. It is basically a process of heating and bending metal where needed, and then welding the pieces together to form the patio bistro set. After it has been completed, the set then has to be coated with a primer and then painted to make it weatherproof.
Tools and Materials Needed:
- Welding safety equipment
- Metal saw
- Metal grinder
- Metal pipes
- Flat metal pieces
- Spray paint-primer
- Spray paint-color
Step 1 - Cut and Mold the Legs
Begin the process of building your own bistro patio set by cutting the pieces of round metal pipe for the legs. Two 3 feet pieces for every chair and two 6 feet pieces for the table.
The legs for the chairs should be about 1 foot high by 1 foot long, so mark them into three sections and heat the areas up that will need to be bent. After they become bright red from the heat, slowly bend them into shape, making sure that you use some type of lever upon the bend so that they do not crease and flatten. The best way to do this is to place the pipe into a larger pipe and place the mark at the end of the larger pipe, then pull down slowly. The legs for the table should be 2 feet high and long, so repeat the steps above to form them into shape.
Step 3 - Assemble the Legs
Begin with 2 chair legs and place them upright next to each other. Cut 4 pieces of flat metal to 1 foot. These will then be placed across the legs to form the seat. Weld them into place, making sure that the ends of the flat pieces are level with the outer edges of the legs. Repeat as many times as required.
The table legs are assembled in the same fashion, except that you will need ten pieces of metal cut at 2 feet. Once again, weld them into place to make the table top. If you want to place a border around the exterior of the top do so now before continuing on to the next step.
Step 3 - Assemble the Back of the Chair
To make the backs of the chairs cut another piece of round pipe to a length of 2 feet. You will need two of these pieces per chair, so cut them accordingly. Mark the pipe at 1 foot and once again heat the metal and then bend it into the curve that you desire. Weld these pieces onto the outside of the leg pieces, facing up rather than down. Cut some flat metal to 1 foot and weld them onto the back pipes, effectively forming a back to the chair.
Step 4 - Prime and Paint
Use the metal grinder to sand down any joints that are not flush and use spray paint primer to coat the entire patio bistro set. Allow the primer to dry and then apply a coat of paint in the same fashion. Once again allow it to dry and then spray on the final coat. Allow the bistro patio set to dry overnight before using them.