Fixing a Broken Chair or Table Leg

Have you ever accidentally broken the leg of a chair or table? Instead of trashing it away, there's a way to fix it! In this guide, I’ll show you how to repair a broken leg on a wooden chair or table. The process is the same for both, and it only takes four main steps:

1. Reattach the Broken Piece
2. Cut Slots for Reinforcement
3. Prepare and Install the Reinforcement Lumber
4. Finish and Paint

Let’s get started!

- Wood Glue

- Trim Router or Plunge Router

- Router Bit Set

- Orbital Sander (or just sandpaper)

- Belt Sander

- Clamp

- Impact driver

Begin by applying wood glue to the broken piece and reattaching it to the chair. Secure it with clamps to hold it in place and apply pressure. This is crucial for creating a strong bond between the broken parts. Allow the glue to dry and harden for at least a few hours.

Once the piece is glued back on, use an orbital sander (or sandpaper if you don't have the tool) to smooth the surface. This step is important because it ensures that when we use a trim router to cut grooves in the leg, everything will go smoothly and precisely.

Next, use a trim router or plunge router with a slot-cutting bit to cut grooves along the leg, crossing the break line.

This is the most crucial step in the repair. Using a router in a free-hand fashion (without supporting jig) can be very challenging, especially if you're not experienced. If you’ve never done it before, practice on a piece of scrap wood first.

These grooves will allow us to insert reinforcement pieces that support the repaired area, similar to how a metal rod supports a broken bone. Cut as many grooves as you can to add more reinforcement and provide stronger support.

After cutting the slots, prepare the reinforcement lumber that will fit into the grooves. This part can be a bit tricky, as you'll need to shape the lumber to fit snugly. Use tools like a table saw, belt sander, or jigsaw to get the right shape. This step is an iterative process—you'll need to shape the lumber, check if it fits, and adjust as needed.

Once your reinforcement pieces are ready, glue them into the slots. For added strength, you can use screws to further secure the pieces. After the glue has dried, sand the surface again to make it smooth. At this point, the chair is structurally sound. If you’re not concerned about the appearance, your chair is ready to use again. But if you want to make it look as good as new, move on to the next step.

Use silicon or a mixture of sawdust and wood glue to fill any small gaps or holes. To finish up, apply stain or paint to the repaired areas. This will help blend the repair with the rest of the chair, making it look like new and ready to use again!