How To Upcycle a Timber Bench

How do you upcycle an old timber bench with tiles?

If you are looking for a bench seat to add some flair to an unused space, upcycling one you already have is a good way to get it. This project — shown by Kyal and Kara — transforms an old timber bench using leftover splashback tiles, by routing a recess into the top, laying in a sheet of fibre cement, and tiling and grouting inside the rebate so the tiles finish flush with the timber.

It is the most involved job in the upcycling series because it combines carpentry with tiling. The two things that decide whether it looks professional are the depth of the rebate and the patience at the grouting stage — get the rebate depth right and the tiles sit flush; rush the curing and the grout stains or cracks.

What you need

How to upcycle the bench

  1. Lay the tiles out on the bench top and move them around until you are happy with the layout. Remember to allow for your grout spaces. Once you are happy, mark around the outside with a pencil.
  2. Run the circular saw at 15mm deep along the marked lines to get a sharp edge and prevent splinters before you use the router.
  3. Route out the inside section of the marks. Set the cutter to 15mm deep, which allows for the tiles and the fibro sheet so you end up with a flush finish. Put your safety glasses and ear protection on for this part. Go slow and let the router do the cutting.
  4. Dust off the rebated section and measure up for the fibro sheet. Score and snap it with a Stanley knife.
  5. Glue the fibro in with Liquid Nails Heavy Duty. Cut the cartridge tip, screw on the nozzle and cut the tip off the nozzle. Using a caulking gun, apply beads of Liquid Nails Heavy Duty into the rebated area, spacing the beads 40cm apart. Lay the fibro straight down on the glue, pushing down firmly to get good contact.
  6. Spread the tile adhesive. Make sure you have cleaned any dust off the fibro. Using a notched trowel — 6mm here — spread the White For Life Ready To Use Tile Adhesive onto the fibro to get an even coat.
  7. Lay the tiles, spacing them with tile spacers. Keep clean water and a sponge handy to wipe away excess adhesive as you go. Leave the tiles to set before grouting.
  8. Grout the joints. Mask around the edges of the rebated section to keep grout off the timber and prevent staining. Mix the grout to a smooth non-slumping paste and wipe it into the gaps with a grouting trowel. Sponge off any excess with clean water and peel off the tape.
  9. Seal the grout once it is dry — at least 3 days. Spray on the grout sealer, leave it to penetrate for an hour, then wipe off any excess with a white cloth. Apply a second coat if needed.

The numbers that matter

Liquid Nails Heavy Duty and the 40cm bead spacing

The 40cm spacing is not a rule of thumb — it is what the product's technical data sheet specifies for beads on broad, flat surfaces. The same sheet gives roughly 3 metres of coverage per cartridge from a 5mm bead, so one cartridge goes a long way on a bench.

Its cure timeline is longer than the video pace suggests: pieces stay repositionable for up to 20 minutes, mechanical fasteners can come off after about 8 hours on porous surfaces, and full cure takes 7 days. The bond strengthens progressively over the first two to three days. For this job that means the fibro is held well enough to tile onto the next day, but the assembly is not at its final strength for a week.

The product is water resistant rather than waterproof, and it is not suitable for permanent water immersion — which is worth knowing if the bench is destined for a covered outdoor area rather than an indoor one. It is also non-slump, so it holds position without sagging.

Tile adhesive: set time before grouting

The video says leave the tiles about 24 hours before grouting. The White For Life Tiling Adhesive technical data sheet specifies 24 to 48 hours to set before grouting begins, so 48 hours is the figure to plan around if the weather is cool or the room is unheated. Before grouting, remove the spacers and rake out any dust, debris and contaminants from the joints — grout will not bond properly over loose material.

Grout: three days before sealing

After grouting, allow the grout to firm up in the joints for about 20 minutes — longer in colder conditions — before cleaning it back with the sponge. Then leave it 3 days before sealing, which matches what the guide says. That is the manufacturer's figure for maximum stain resistance from the sealer, and it is the step most likely to be rushed.

Coverage, if you are buying: one 410g cartridge covers about 2m² and the 1.4kg tub about 6m², based on 300mm × 30mm tiles with a 5mm joint depth and 3mm joint width. A bench top uses a fraction of a tub.

Grout sealer

The grout must be dry, clean and free of contaminants such as waxes, sealers or finishes before the sealer goes on, and free from cracks or chips. Spray it liberally to saturate the grout, let it penetrate for 1 hour, then wipe overspray off the tile face with a clean cloth within 2 hours of application. A second coat gives maximum protection — apply it, allow another hour, and wipe the overspray again. Do not apply the sealer below 10°C.

Reseal annually, or whenever the grout has been scrubbed hard, and clean the tiles and grout regularly with White For Life Tile & Grout Cleaner to avoid a build-up of soil that leads to staining.

Limitations — what this bench is and is not

Getting the rebate depth right

The 15mm figure in this project is specific to 4.5mm fibro plus the particular tiles used, and it is worth working out yours before you cut. Add together the fibre cement thickness, the adhesive bed the notched trowel will leave, and the tile thickness. Cut the rebate to that total and the finished tiles sit flush with the surrounding timber. Cut it too shallow and the tiles stand proud with an edge you will catch on; too deep and you get a tray that collects crumbs.

Running the circular saw along the pencil lines first is worth the extra few minutes. It severs the timber fibres at the boundary, so when the router reaches the edge it cannot tear a splinter out beyond the line.

Safety: the construction adhesive is a flammable liquid

Three of the four Selleys products in this project carry only a skin-sensitisation classification. White For Life Ready To Use Grout, Grout Sealer and Tile & Grout Cleaner are each Warning — H317, may cause an allergic skin reaction. That is not irritation: it is generally permanent once acquired, and it is built from repeated casual contact. Grouting is done with a trowel and then a sponge worked back over the whole top by hand, which is as much contact as this project involves. Wear gloves for the grouting and the sealing.

Liquid Nails Heavy Duty is classified Danger:

H225 is not a warning about naked flame in the room. It is the vapour that ignites, the vapour is heavier than air, and it pools at floor level — so an ignition source across the shed and low down still counts. This project is done in a garage or a workshop, which is where the gas water heater pilot, the bar heater and the fridge compressor live, and where people close the roller door because it is cold. Run the beads with the door up and the air moving.

H336 lands badly on the sequence this project uses. You run beads of solvent adhesive into a rebate, then you are back on the router, the circular saw and the Stanley knife. Drowsiness and dizziness from accumulated solvent vapour is the last thing you want while trimming fibre cement. Glue, then let the space air out before you pick a power tool back up — and the safety glasses the page already specifies for routing should stay on for the beads, because a cartridge under gun pressure can spit and H319 is serious eye irritation.

If the bench is staying indoors or under cover, there is a lower-hazard option in the same range. Liquid Nails Fast Grab is water-based, low odour, positioned by Selleys as the indoor construction adhesive, and carries only Warning — H317 with no flammability classification at all. It is rated for interior and sheltered exterior work protected from moisture — which is the same covered spot this page already recommends for the finished bench. Check its gap-bridging and set figures against your rebate before you swap, since the 40cm bead spacing quoted above is Heavy Duty's number.

Poisons Information Centre — 131 126 in Australia, 0800 764 766 in New Zealand.

Common questions about tiling a timber bench

How far apart should the Liquid Nails beads be?

40cm on broad flat surfaces, which is what the product's technical data sheet specifies.

How much does one cartridge cover?

About 3 metres of bead at a 5mm diameter.

How long before the fibro is properly stuck down?

It is repositionable for up to 20 minutes and holds well enough to work on within hours, but full cure is 7 days, with most of the strength arriving over the first two to three days.

How long do the tiles need before I can grout?

The White For Life Tiling Adhesive data sheet specifies 24 to 48 hours to set before grouting. Allow the longer end in cool conditions.

Do I need to remove the spacers first?

Yes — remove the spacers and rake out dust, debris and contaminants from the joints before grouting.

How long before I sponge the grout back?

Let it firm up in the joints for about 20 minutes, longer in colder conditions, then clean it back.

Why mask the timber edges?

To keep grout off the timber, which prevents staining. Peel the tape off while the grout is still workable.

How long before I can seal the grout?

At least 3 days. That is the manufacturer's figure and it is required for maximum stain resistance from the sealer.

How do I apply the grout sealer?

Spray liberally to saturate the grout, let it penetrate for 1 hour, then wipe the overspray off the tile face with a clean cloth within 2 hours. A second coat gives maximum protection. Do not apply below 10°C.

How often should I reseal?

Annually, or whenever the grout has been scrubbed hard.

Can the bench live outside?

The grout is not suitable for areas frequently immersed in water and needs 3 days before water exposure, and the construction adhesive is water resistant rather than waterproof. A covered spot is a much better bet than an exposed one.

How deep should the rebate be?

Add the fibre cement thickness, the adhesive bed and the tile thickness together. In this project that came to 15mm using 4.5mm fibro.

What related projects use the same products?

See how to tile a kitchen splashback, how to grout tiles and how to seal grout.

What is the topic of this Selleys page?

The page, titled "How To Upcycle a Timber Bench," is a Selleys guide about transforming an old timber bench into a stylish and practical piece of furniture through upcycling.

What does the Selleys guide promise to help readers achieve?

According to the page description, the guide promises to make upcycling easier by showing readers how to follow steps to transform an old timber bench into a stylish and practical piece of furniture.

Which Selleys product could be used to fill damage in a timber bench before upcycling?

Selleys No More Cracks Wood Filler is suitable for filling interior timber damage; it is durable, easy to sand, and can be stained and painted to match the timber.

Is there a Selleys product for rebuilding or reshaping damaged timber sections on a bench?

Yes, Selleys Knead It Multipurpose is a hand-kneadable epoxy putty that can rebuild, reshape, or repair timber surfaces, and once cured it can be drilled, sawed, and painted.

What product might be used for structural bonding when repairing or assembling a timber bench?

Selleys Liquid Nails Heavy Duty is a construction adhesive suitable for timber bonding, offering strong adhesion for furniture assembly or repair work.

After repairing a timber bench, what finishing step is suggested?

After any repairs have dried and been sanded, applying stain and varnish products is suggested to restore the bench's appearance.

Who publishes this timber bench upcycling guide?

The guide is published by Selleys, an Australian adhesives, sealants and fillers brand and a division of DuluxGroup (Australia) Pty Ltd, founded in 1939 in Sydney, Australia.