Important tips when assembling teak furniture.
Good news. Most of our furniture is pre-assembled. You will usually only need to perform the final assembly of the larger sections. Stacking chairs and folding tables are all completely pre-assembled. OK, here are the tips. Let’s begin with a typical chair for example.
Tools, etc. needed.
Scissors and box cutter to remove packaging. Be careful not to cut too deeply into boxes.
Rubber mallet to tap large sections together.
Smooth faced hammer to tap in wood dowels.
Round Bastard File - may be needed to clean out dowel holes. After tapping all the sections together, we advise cleaning out all the holes with a round bastard file in order to remove any wood debris left in the holes and for ease of inserting wood dowels.
GORILLA GLUE (original formula). Usually one small bottle is enough for 8 chairs and 1 table.
Cheap artist paint brushes to spread the glue.
Old cloth rags to clean off glue and for final wipe down of all wood surfaces prior to use.
Paint thinner or mineral spirits to clean off excessive glue. 1 QT
Dish soap and wet cloth to wipe off teak dust from all wood surfaces after assembly to prevent staining your cushions and pavement below the furniture.
Let's Get Started.
1. Find a flat area for assembly and preferably comfortable as to shade or sun. Layout cardboard or old cloth to work on. The best scenario would be to do the assembly on an outdoor table so the work can be done without bending over too long. A little background music and some cold drinks can also be nice. Estimated time to assemble most products averages about 30 minutes or so.
2. Assemble (tap) all of the wood sections together. Do not install the wooden dowels immediately. Do not apply glue immediately.
3. There are usually small decals that either have numerals, letters or colors that need to match up. This way all parts will fit properly. Example: F3 must mate with F3. Or B2 must mate with B2. Or green must mate with green, and so on. Never mix parts from one box with a separate box. Parts are not interchangeable. So only open one box at a time to assemble.
4. Now the chair is mostly all assembled. Take a close look at the chair to make sure all looks good to you. If so, insert a round bastard file into each dowel hole and ream out wood debris to be sure the dowels will tap in easily. Then tap the sections apart slightly enough to apply a little glue to the mortice and tennon connections. If using GORILLA GLUE (original formula) you will need to dampen the wood on one side first, and then apply the glue. ONLY A SMALL AMOUNT OF GLUE IS NEEDED. DO NOT OVER GLUE.
We recommend applying Gorilla Glue (original formula) at all the joints and dowels where the wood meets wood. Just a little smear is all that’s needed. This is optional, but this assures long term sturdiness. If too much glue is applied you will notice some frothing. No problem. Just wipe or scrape away with paint thinner or mineral spirits. Or once dried, just scrape away the froth with putty knife and finally sand with 220 grit sandpaper.
Note: Before applying any glue you must moisten all joints (usually the female end) with water/moisture. It is the moisture that causes a chemical reaction to the Gorilla Glue.
When cutting dowels, place a thin washer or thick paper while cutting off excess.
Bottom of Legs - In order to prevent water from wicking/staining the bottom of the legs we recommend steel leg levelers on the tables and tap-on plastic gliders on chairs. The levelers on the tables are great for leveling the table top surface for beverages and food stability.
Applying teak sealers or teak oil? If so, after assembly we recommend letting the furniture acclimate to the weather for approximately 1 week. The sun will reduce the mill glaze (smoothness) and allow better adhesion of your new teak sealer product(s). We recommend SEMCO Sealer, Honeytone (golden color). One gallon is the best deal in the long run for the initial and subsequent sealing. For our detailed sealer or oil instructions, visit https://www.wood-joy.com/teak-outdoor-furniture-care/
Storage of Cushions - While rain water does not damage our cushions, we advise that you store them during inclement weather. This will prevent water saturation in the internal foam and will keep them looking great for many years. Wipe off teak dust from all wood surfaces after assembly to prevent staining your cushions and pavement below the furniture. Use Dish soap and wet cloth or wipe on mineral spirits.
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