DIY Patio Chair Makeover: Refinishing & Reupholstering with Duck Canvas

Updated at: 06/02/2025

Tired of that faded, worn-out patio chair taking up space on your deck? Give it a new lease on life with this easy DIY makeover! We'll transform a tired old chair into a stylish and durable piece of outdoor furniture using the surprisingly versatile and weather-resistant material: duck canvas. This project is perfect for those looking to refresh their outdoor space without breaking the bank, and it's a fantastic way to add a personal touch to your patio décor. You'll be amazed at the difference a little elbow grease and some creative repurposing can make.

This guide will walk you through the complete refinishing and reupholstering process, from preparing the chair frame to sewing and attaching the new duck canvas fabric. Ready to get started on breathing new life into your outdoor seating? Let's dive into the step-by-step instructions and revitalize that old patio chair!

Preparation and Safety Guidelines

Tools Needed
  • Duck canvas
  • Heavy-duty needle (jeans/denim needle or leather needle)
  • Sewing machine
  • Warm soapy water
  • Rust-Oleum paint and primer (flat black)
  • Screwdriver
  • Hammer
  • Metal plate (existing bracket)
  • Pen
  • Awl (optional)
Safety Guidelines
  • Always wear appropriate safety gear, including eye protection and a dust mask, when sanding and using cleaning solutions.
  • Work in a well-ventilated area. Fumes from paints, stains, and cleaning products can be harmful.
  • Use caution when handling sharp objects like staples and the upholstery removal tools. Consider wearing work gloves.

Step-by-Step Instructions

  1. Prepare the Chairs

    • Remove existing fabric and metal brackets from patio chairs using a screwdriver.
    • Clean the chair frames with warm soapy water.
    • Refinish chair frames using Rust-Oleum paint and primer in flat black. Allow to dry completely.
    Refinish chair frames using Rust-Oleum paint and primer in flat black. Allow to dry completely.Refinish chair frames using Rust-Oleum paint and primer in flat black. Allow to dry completely.Refinish chair frames using Rust-Oleum paint and primer in flat black. Allow to dry completely.
    Prepare the Chairs

  2. Create Fabric Patterns

    • Use the old fabric as a template to create patterns for the new fabric pieces. Add seam allowance (1.5 inches recommended for finished edges).
    Use the old fabric as a template to create patterns for the new fabric pieces. Add seam allowance (1.5 inches recommended for finished edges).
    Create Fabric Patterns

  3. Cut Duck Canvas

    • Cut the duck canvas according to the dimensions obtained from the template. For larger pieces, consider cutting one long piece and folding instead of sewing two rectangles.
    Cut the duck canvas according to the dimensions obtained from the template. For larger pieces, consider cutting one long piece and folding instead of sewing two rectangles.
    Cut Duck Canvas

  4. Sew Backrest Fabric

    • Sew the bottom hem with a 0.5-inch seam allowance. Press open the seam and then fold over again for a finished edge, sewing along the folded edge.
    • Add a decorative stitch along the top folded edge at a 0.5-inch seam allowance.
    • Fold and sew the side hems with a 0.5-inch seam allowance, then fold over again at a 1-inch seam allowance and stitch in the ditch to create a finished edge. This 1-inch section will be attached to the chair.
    • Create a small pocket along one side hem to accommodate the stabilizing rod from the original design.
    Create a small pocket along one side hem to accommodate the stabilizing rod from the original design.Create a small pocket along one side hem to accommodate the stabilizing rod from the original design.Create a small pocket along one side hem to accommodate the stabilizing rod from the original design.Create a small pocket along one side hem to accommodate the stabilizing rod from the original design.
    Sew Backrest Fabric

  5. Prepare Fabric for Attachment

    • Using the metal bracket as a guide, mark and create holes in the new fabric where the screws will go. An awl is recommended, but a screwdriver and hammer can be used as a substitute.
    Using the metal bracket as a guide, mark and create holes in the new fabric where the screws will go. An awl is recommended, but a screwdriver and hammer can be used as a substitute.
    Prepare Fabric for Attachment

  6. Attach Backrest Fabric

    • Attach the new fabric to the chair frame using the existing metal brackets and screws.
    Attach the new fabric to the chair frame using the existing metal brackets and screws.
    Attach Backrest Fabric

  7. Repeat for Seat

    • Repeat steps 4-11 for the seat.
    Repeat steps 4-11 for the seat.
    Repeat for Seat

Read more: Sew a Lined Expandable Storage Bag: Easy Tutorial

Tips

  • Use a heavy-duty needle to avoid breaking needles when sewing with thick fabric like duck canvas.
  • Maintain even tension on both layers of fabric when sewing to prevent slippage.
  • Pressing open seams creates a neater finish.

Common Mistakes to Avoid

1. Insufficient sanding

Reason: Not sanding the chair frame properly before applying stain or paint leads to an uneven finish that may peel or chip.
Solution: Sand all surfaces thoroughly with progressively finer grit sandpaper until smooth before applying any finish.

2. Using the wrong type of fabric

Reason: Choosing a fabric that isn't durable enough (like thin cotton) for outdoor use will lead to quick wear and tear from sun, rain, and general use.
Solution: Opt for a heavy-duty outdoor fabric like duck canvas or Sunbrella for increased durability and weather resistance.

3. Inadequate preparation for reupholstering

Reason: Not accurately measuring the chair and cutting the fabric with precise measurements results in a poorly fitted and unprofessional-looking finish.
Solution: Take meticulous measurements, create detailed patterns, and carefully cut the duck canvas, leaving seam allowance for a perfect fit.

FAQs

What type of paint is best for refinishing patio chairs?
For outdoor furniture, choose a durable exterior paint designed to withstand weather. Acrylic latex paints are a popular choice because they're relatively easy to apply and clean up, and offer good weather resistance. Consider a paint specifically formulated for metal or wood, depending on your chair's material.
How do I measure for new duck canvas fabric?
Measure each chair piece individually (seat, back, etc.) adding extra inches for seam allowance (at least 2 inches on all sides). It's helpful to create paper templates first to ensure a good fit before cutting the duck canvas.
Can I use a staple gun for reupholstering?
Yes, a heavy-duty staple gun is essential for attaching the duck canvas to the chair frame. Make sure to use staples appropriate for the material of your chair frame (e.g., galvanized staples for metal).