How to Redo Cast Aluminum Outdoor Furniture

Patio furniture has to face four seasons and all sorts of inclement weather. These punishing conditions can quickly degrade the surface and structure of any material. Metal furniture stands up better to harsh conditions, but ferrous metals like iron and steel can rust. Aluminum does not rust, and cast aluminum has a strength comparable to ferrous metals. If your cast-aluminum patio furniture has become weathered with time and use, you can redo it with the right materials and technique.

  1. 1.

    Sand your cast-aluminum patio furniture with moist, 120-grit sandpaper, or a handheld rotary tool with a 120-grit sanding accessory, until it has a dull, even surface.

  2. 2.

    Spray off any sanding debris with a garden hose.

  3. 3.

    Dry the surface of the furniture with a clean cloth.

  4. 4.

    Clean the sanded surface of the furniture with mineral spirits applied with a clean cloth.

  5. 5.

    Move the furniture to a well-ventilated area out of direct sunlight.

  6. 6.

    Put on a respirator.

  7. 7.

    Spray a coat of epoxy primer over the entire surface of the furniture. Allow the primer to dry completely according to the manufacturer's instructions.

  8. 8.

    Spray a coat of polyurethane topcoat paint to the entire surface of the furniture. Allow the topcoat paint to dry completely according to the manufacturer's instructions.

    Things You Will Need

    • 100-grit sandpaper or handheld rotary tool with fine-grit sanding accessory

    • Garden hose

    • Clean cloths

    • Mineral spirits

    • Respirator

    • Epoxy primer

    • Polyurethane paint


    Epoxy primer and polyurethane paint emit hazardous fumes. Ensure that your respirator has fresh filters and working seals. Although some sources say that primer is unnecessary when an aluminum surface is properly prepared and the proper paint is chosen, topcoat without primer is not likely to stick well, especially on furniture exposed to the outdoor elements.

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