Converting car parts into interior items is not just a trend, but a real upcycling philosophy that allows you to give a second life to parts that would otherwise be melted down. Car rack chair has become a cult object in the loft design industry, combining brutal aesthetics, incredible durability and functionality. Such products can often be found in fashionable barbershops, garage workshops and modern apartments where industrial charm is appreciated.
Creating such furniture with your own hands is a fascinating process that requires a minimum set of tools and basic skills in working with metal. Unlike buying ready-made designer items, making your own allows you to have complete control over the quality of materials, seat firmness and color scheme. In this article we will look in detail at all the stages of turning an old shock absorber strut into a comfortable and reliable chair.
⚠️ Attention: Before starting work, make sure that the gas chamber of the rack is completely discharged. Attempting to saw or drill a component under pressure may result in injury!
Selection and preparation of a car rack
The basis of the future chair is shock absorber strut, which must have sufficient height and rod diameter for stability. Racks from SUVs or large sedans are best suited for these purposes, as they are more massive and look more impressive. When choosing a part at a disassembly site, pay attention to the condition of the spring: if you plan to use it as a design element, it should not be heavily compressed or have signs of corrosion.
The preparation process begins with a thorough cleaning. All dirt, oil residues and old paint must be removed. To do this, you can use a metal brush, a drill attachment, or chemical removers. If you want to preserve the original appearance of the metal, sandblasting is suitable, which will ideally clean the surface of rust, but will not damage the structure of the metal.
An important step is decompression gas stop. Even if the rod does not move, pressure may remain inside. To safely vent the gas, you need to carefully drill a small hole in the rack body (not in the rod!) in the lower part, having first securely secured the part in a vice.
Is it possible to use a rack with a broken oil seal?
Yes, to create a chair, the tightness of the shock absorber does not matter. The main thing is the integrity of the metal of the rod and body, as well as the absence of through corrosion, which can weaken the structure.
- 🔧 Choose a stand from 40 to 60 cm long for optimal height.
- 🧼 Degrease the surface with acetone or white spirit before painting.
- 🛡️ Use a respirator when working with chemical cleaners.
Required tools and materials
To complete the project, you will need a basic DIY kit, which can be found in any garage. The key element is the welding machine, since it is welding that will ensure the solidity of the structure. If you don't have welding experience, heavy-duty bolting can be used, but this will require more complex marking and drilling into thick metal.
Particular attention should be paid to the material for the seat. Traditionally, solid wood, high-density plywood or sheet metal are used. For loft style A board made of oak, larch or even a cut of wood treated with oil is ideal. A metal seat will require extra effort in cutting and sanding the edges.
Don't forget finishing supplies. You will need a metal primer, enamel (hammer paint is often used for a shagreen effect) and wood varnish. You will also need fasteners: bolts, nuts and washers, if you do not plan to weld the seat tightly.
☑️ List of tools
Chair frame assembly technology
Frame assembly is the process of connecting the shock absorber to the base. The simplest option is to weld a metal plate to the bottom end of the rack, which will serve as a support. However, for greater stability and aesthetics, a cutting method is often used: the lower part of the rack is cut into several “petals”, which are folded outward and welded to a round or square base.
If you are making a chair on wheels (mobile version), a flange is welded to the bottom of the stand, to which an office base with casters is attached. In this case center of gravity must be calculated accurately so that the chair does not tip over when tilted. In this case, the shock absorber rod is usually fixed in a compressed state or removed, if the design allows.
For a stationary option, three or four additional legs are often used, welded to the rack body at an angle. This creates a tripod or stool effect. It is important to maintain symmetry when welding so that the chair does not wobble. After welding, all seams must be cleaned with a grinder and sanded to obtain a smooth surface.
To prevent chair legs from scratching the floor, weld small rubber pads to their ends or use adjustable plastic supports that can be purchased at a furniture store.
| Base type | Difficulty | Sustainability | Material |
|---|---|---|---|
| Single plate | Low | Average | Steel 5-8 mm |
| Tripod (braces) | Average | High | Steel pipe |
| Office cross | High | High | Aluminium/Steel |
| Square frame | Average | Maximum | Profile pipe |
Manufacturing and installation of the seat
The seat is the element with which the user is in contact, so his comfort and safety come to the fore. If you use wood, make sure the board is well sanded and free of splinters. The optimal thickness of a wooden circle is 30-40 mm. To attach wood to metal, it is best to use hidden fasteners or bolts from below so that the caps do not spoil the appearance.
The metal seat can be made of a thick sheet of steel. It can be left matte, polished to a mirror finish, or artificially aged. Often, a recess or perforation is made in the center of a metal seat, which adds manufacturability to the product. When installing a metal circle, it is important to provide thermal insulation, since the metal cools quickly and can be unpleasant to the touch.
The seat is attached to the rod or the top platform of the rack through an adapter plate. This plate is welded to the post and the seat is bolted to it. This solution allows you to replace the seat in the future or remove it for transportation. The diameter of the seat should match the diameter of the top of the rack or be slightly larger for overhang.
⚠️ Attention: When drilling holes in a wooden seat, use feather drills and place a block on the back side to avoid chipping when the drill comes out.
Painting and finishing
The final appearance of the product depends 80% on the quality of painting. For metal parts, alkyd enamels or specialized rust paints are best suited. If you want to get the effect shagreens, use hammer paint, which hides minor welding defects and metal irregularities. Apply the paint in 2-3 thin layers, allowing each layer to dry according to the instructions.
A wooden seat requires protection from moisture and mechanical stress. You can use oil with hard wax, which emphasizes the grain of the wood, or polyurethane varnish to create a durable film. For the loft style, the technique of brushing (aging) is often used or the wood is burned with a gas burner and then varnished.
Assembling painted parts should be done carefully so as not to scratch the fresh coating. Bolted connections can be decorated with decorative caps or left as is if chrome-plated fasteners are used. Final polishing of metal surfaces with a soft cloth will give the product a marketable appearance.
High-quality surface preparation (degreasing and priming) is more important than the number of layers of paint. Without primer, even expensive enamel will quickly peel off.
Design options and upgrades
The basic design of a post chair can be modified endlessly. A popular solution is to add a backrest, which can be made from a curved strip of metal or a piece of leather stretched over a frame. You can also integrate a cup holder into the design by welding a ring to one of the supports.
To create a set of furniture in the same style, tables are made using shorter posts or springs. Combining different types of shock absorbers (for example, from a motorcycle and from a truck) allows you to create interesting contrasts in size. Some craftsmen integrate LED lighting into the base of the stand, creating a floating effect or illuminating the structure from the inside.
Don't forget about ergonomics. The height of a standard chair is 45-50 cm. If the stand is too high, it can be shortened by carefully sawing off part of the body, but this will require re-welding and painting the end. If it is low, you can increase the height by using a thicker seat or high support legs.
- 🎨 Use stencils to apply auto brand logos to the seat.
- 💡 Add a USB port to the side to charge gadgets (requires electrician skills).
- 🧵 Cover the seat with leather with decorative stitching for comfort.
Frequently asked questions (FAQ)
Do I need to remove the spring from the strut?
No, it is not necessary to remove the spring. Many people leave it as a decorative element, having previously painted it in a contrasting color. However, if you are making a chair with an upholstered seat, the spring is often removed to reduce the overall height of the structure.
How much load can this chair withstand?
Car racks are designed to support the weight of the car on each wheel. Even taking into account dynamic loads, one rack can easily withstand 300-500 kg of static load, so for a person its strength is more than enough.
What is the best way to attach wood to metal?
The best option is to use countersunk bolts (to recess the head) and nuts on the reverse side. It is advisable to lay a thin rubber or cork gasket between the metal and the wood so that the wood “breathes” and does not rot from contact with the metal.
Is it possible to make a chair without welding?
Yes, if you use a ready-made office cross with a fastening mechanism and a corresponding flange that fits onto the stand. In this case, the connection will be bolted. However, finding a flange that perfectly matches the diameter of a specific rack can be difficult.