Learn how to restore cast iron items including fireplaces, patio furniture, railings, and even pots to keep them looking great for years to come.
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Learning how to restore cast iron is essential to giving old items a new lease of life and reducing the need for useless replacements. Cast iron is a strong, highly durable metal that is extremely versatile and can be used to make everything from pans and pots to garden furniture, gates, and railings.
Over time, defects appear on the surface of cast iron products, which give them individuality and make them especially suitable for the interior of old houses. With proper care, cast iron can last for hundreds of years, but with improper care, cast iron products will begin to rust and become unusable.
Roger Hunt, author of The Old House Handbook, said: “Gates, railings and other cast iron items are as much a part of our architectural heritage as our building stones and bricks. Although these metal items may appear durable, if not maintained they can corrode and eventually break.”
People often get confused about whether metal objects are made of cast iron, wrought iron, or steel. So you should first make sure that you are actually trying to repair cast iron, although the same repair methods can usually be used.
If you are restoring a heavy skillet or pot, it will almost certainly be cast iron, but items such as furniture or architectural ironwork are more difficult to identify.
“Wrought iron is a low-carbon forged alloy that must be worked by hand or machine. It is traditionally used for architectural elements such as grilles and balconies – even the Eiffel Tower is made of wrought iron. The term is also incorrectly applied to the working of modern steel, which is a more refined version of wrought iron,” explains Antiques Roadshow expert Mark Allum.
“People get confused because many objects of similar nature are made using either one process or a combination of two. Hand-forged buildings are completely different from cast iron objects, which are made using a mold.”
Douglas Kent, director of technology and research at the Society for the Preservation of Historic Buildings, added: “Castings are often held together with nuts and bolts or interchangeable components. Cast iron is more brittle and has lower tensile strength than wrought iron, but it is quicker and easier to manufacture. The parts have deeper profiles and a more uniform appearance.”
Cast iron is ideal for mass-produced items such as drainpipes, fireplaces, and door knockers. Unlike wrought iron, cast iron has never been completely replaced by steel.
When deciding how to restore old cast iron cookware, you need to consider the value of the item, its use, and the finish – is it painted or unpainted?
You will also need to assess the extent of the damage. Peeling paint or rust on cast iron can be easily repaired if the cast iron is otherwise in good condition. However, repairing damaged or missing parts may not be possible.
“Another potential problem is cracking of the cast iron due to impacts or casting defects,” Kent said.
“Cast iron is difficult and uneconomical to repair, so if a decorative section is completely missing, there is little hope of restoration. However, a skilled welder can restore missing sections or hidden structural elements,” Allum said.
Kent advises that the best way to repair cast iron is by cold piercing. “A specialist company can take a mould from the cleaned original and recast the component.” This method is particularly useful for items with repeating sections, such as handrails or balusters.
If repairs are not needed, cast iron can usually be restored by stripping the paint, sanding and refinishing, but some projects require more attention than others.
If the item is valuable or is an important piece in your home and needs repair, then it is best to hire a professional to restore the cast iron.
Whether your cast iron fireplace is original or you are planning to install an antique design, it may require some restoration work.
“The incredible demand for fireplaces in the Victorian era meant that millions were produced, so there are plenty to choose from at junkyards, dealers and auctioneers. Some fireplaces can be bought very cheaply, but the key factor is the degree of damage,” Allum said.
Cast iron fireplaces can be painted or coated with iron sealant or black grate polish to achieve the signature black finish.
If the paint on the fireplace you are repairing is damaged or peeling, you will need paint stripper to remove it. This is not a pleasant job, and you need to be extremely careful when working with such caustic chemicals. Do not use a blowtorch, as you may damage the paint or damage the fireplace.
Apply the paint stripper exactly as directed, leave it on for the specified time, then scrape off the paint with a scraper. You may need to apply it several times and use a stiff brush to achieve crisp detail.
Restoration expert Helen Clare says: ‘To remove rust or stubborn stains, cut a piece of medium-strength steel wool and rub the rust, then put on protective gloves and rub gently until the rust disappears.’
When priming the final surface of a cast iron fireplace, use fine steel wool, but do not use water to clean the surface. If the surface gets wet, wait until it is completely dry before applying paint, polish or paste.
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Cast iron garden furniture is left outdoors for long periods of time and will show signs of wear over time. Cast iron garden furniture is often purchased from antique stores, and although it has an attractive patina, it usually requires some maintenance to keep it in good condition.
Common problems with cast iron garden furniture include peeling paint, rusting mounting bolts, and dirt and algae build-up on the surface.
“As with most renovations, the initial work was hard and involved a lot of time spent scraping, sanding and cleaning,” said Claire.
Rusty bolts need to be removed and replaced. If the wrench doesn’t loosen the bolt, spray it with tightening oil, then wait and try again. Hammering will help break up the corrosion holding the nut and bolt together, but be careful not to do this with cast iron, which is brittle and prone to cracking.
As a last resort, Claire suggests using a hacksaw to cut through tough nuts and bolts. Replace with new, corrosion-resistant ones.
The next step in restoring cast iron patio furniture is to give it a thorough cleaning. If there is algae, apply a fungicide or bleach with a brush or sponge. Claire said: “Leave it for 24 hours, then rinse with water.”
If the paint is only peeling in small areas, there is no need to remove all the paint from your patio furniture before repainting. “Wear protective gloves and use a steel wool brush to remove any peeling paint and create a strong base for the new coat of paint,” says Claire.
As the paint wears away, the metal is exposed to the elements and weather, causing a powdery coating to form. “Use a sanding block and wet and dry sandpaper to sand down unstable surfaces until a solid base is created.”
The last step before painting is to wash the furniture with hot soapy water, then wait until it is completely dry before applying a coat of paint. In some cases, you will need to apply a primer first – read the instructions carefully.
Cast iron gates and railings make an important first impression of your home, so if they look dated, restoring them will improve the overall look.
“If a metal surface has been painted several times, fine details may be hidden. So if there is a lot of paint build-up or large areas of rust, it is best to strip all the original paint,” says Claire.
This job can be done with a chemical paint stripper. You can use a heat gun, but old paint may contain lead. If you are dealing with a removable item, such as a gate, you may want to send it to an industrial paint removal company.
If the paint has accumulated less and is only slightly peeling, it is easier to leave it in place and repaint.
“Use a metal scraper to remove bubbles and loose paint. Remove rust with a steel brush, then buff the surface with steel wool,” says Claire. “Once all the loose paint flakes have been removed, smooth the edges of the remaining strong paint with sandpaper to avoid unsightly ‘steps’ in the finished paint.
Wipe the metal with a damp cloth and, if necessary, apply a rust remover, carefully following the manufacturer’s instructions.
Before applying metal primer, make sure the metal is completely dry, then apply two new coats of paint.
When cast iron pots and pans lose their original shine, moisture in the air can cause them to rust. However, with a little effort, you can restore the surface and make the pan usable again. This technique should not be used on enamel cookware.
You can also use vinegar – mix equal parts white vinegar and water and soak the item for up to eight hours, checking regularly until all the rust is gone.
After removing rust, rinse the pan thoroughly and dry it completely before re-treating the surface.
Seasoning is the final step in restoring your cast iron skillet. Seasoning creates a layer of oil on the pan, giving it a shiny black color that protects the metal and prevents food from sticking while you cook.
“To season a pan, wash it in warm soapy water, rinse thoroughly and leave to dry. Then pour a little oil into the pan and rub the oil all over the pan with a clean cloth so that the pan is evenly coated in a thin layer of oil,” explains James Devonshire, director of Daylesford Cookery School. “Then place it upside down on a rack in the oven and bake on a high heat for an hour. Allow it to cool completely in the oven before using.”
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Melanie has been working in home and garden media for twenty years. Previously, she was the editor of Period Living magazine and worked for Homes & Gardens, Gardening Etc, Real Homes, and Homebuilding & Renovating before focusing on gardening as the senior editor of Gardening Know How. An avid gardener, Melanie has tried just about every vegetable with mixed results. Often, the simplest things can be confusing, which may explain why she can’t figure out how to grow zucchini.
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