Most of the benches I have sold slats for have been just wood slats on the seat and back. I was hesitant to work with any of the benches with the metal insert wraped in wood because the slightest error in measuring could spell disaster. Shipping these slats is a big deal, its a 4' box and weighs around 25 lbs so I never wanted a customer to ship a set back.
Before
Last month I had a request do one such bench, and the customer seemed so precise and confidant in his measurements that I figured I would give it a try. There is no joinery in the back pieces that wrap the metal rectangle, the shorties are just butted against the full length top and bottom. The short pieces actually don't bear any weight or stress, they are just there as fillers and only held in by two small wood screws from behind.
Detail of the short section/filler pieces - Only held on by two tiny screws!
The owner used a stain, and two coats of polyurethane and I think it came out fantastic! I particularly like that the metal doesn't look uniform and painted, I'm guessing he used a clear rust sealer made by Rustoleum I've seen at the Depot for use on garden tools. I honestly think this bench looks better now than when it was brand new. Great work Mike!!
Looking good!!