Rust-Oleum Projects

Outdoor Patio Love Seat

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  • Estimated Time

    10 Hours

  • Challenge Level


  • Tools & Supplies

    • 2 x Deep Seat Outdoor Cushions
    • 4 – 2x4x8’ Cedar Boards
    • 9 – 1x4x8' Cedar Boards
    • 1 ¼” Exterior Pocket Hole Screws
    • 1 ¼” Exterior Wood Screws
    • 2 ½” Exterior Pocket Hole Screws
    • 2 ½” Exterior Wood Screws
    • Drill
    • 7/64” Drill Bit (for pre-drilling)
    • Mitre Saw
    • Kreg Jig
    • Table Saw
    • Safety Equipment
    • Heat Torch Optional for Shou Sugi Ban Technique
    • Wire Brush Optional for Shou Sugi Ban Tecnique

There is nothing more relaxing than sitting on the patio on a comfy love seat you just built. This DIY project by Cask Woodworking is exactly that, but with an exciting twist – the Shou Sugi Ban technique!

For the love seat portion of this project, you can reference RogueEngineer’s Outdoor Loveseat plans here.

  1. Cut wood to size, as outlined in the loveseat plan.
  2. Assemble the sides. Pro Tip: Having a set of setup blocks will make it easier to ensure your 2x4x29-5/8” pieces are 1/2“ from the ground.

  3. Assemble the frame. Work on a flat surface to ensure your frame is square.
  4. Install the seat. Those setup blocks will assist you here when you need the 1/4” and 1/2” gaps.

  5. Install the back. Again, using the setup blocks to ensure proper spacing will go a long way. Take precaution when screwing the pocket hole screws into 3/4” material as you don’t want to strip the pocket hole and reduce the effectiveness of the joint.

  6. Sand the loveseat at 80 grit and remove any glue that has squeezed out.

  7. Shou Sugi Ban! When applying the flame across the wood surface, move across the wood in a methodical pattern to ensure an even burn. You’ll know it’s time to move on when the wood starts to blister. Caution: Be sure to woodburn outside and read all warning labels on equipment.

  8. Take a wirebrush and move with the grain to clean off the burnt wood. Brown wood will start to appear. Continue brushing until your desired colour.

  9. Remove remaining burnt wood residue and use a 120 grit sanding pad to clean up any scratch marks or areas you couldn’t reach with your brush.

  10. Apply Varathane Diamond Wood Finish – Outdoor over the entire love seat to seal and protect.

  11. Let dry and enjoy!

Visit Rust-Oleum Canada on Instagram and Cask Woodworking on YouTube for more tips and inspiration!