Building a Custom Rustic Steel Dining Table Base

Today, I’m building a custom rustic steel dining table base, from welding and acid treatment to creating unique rust patinas with vinegar, and finishing with weighted concrete for stability

I just finished tack welding these frame pieces together, and now comes the tricky part. I need to be really careful as I weld this thing up – I don’t want to add too much heat and warp it out of plane. Since this is what’s going to support the glass top, it needs to stay reasonably flat. So I’m taking my time with it, welding one section, letting it cool down, then hitting the opposite side. Just working my way around methodically.

After getting the basic box welded up, I decided to build a trough for it to sit in. This will help prevent tipping and hold everything more securely in place. Then I’ll add a cap on top so you’re not just looking down inside the hollow box – just a nice rusty cap to finish it off.

The Rust Treatment Process

Once I had the steel box fully welded, I sprayed it down with muriatic acid. This stuff just eats right through all that mill scale, and honestly, I’ve found it way easier than trying to grind and buff everything off. Plus, it leaves a smoother finish. Since I’m working with acid, I made sure to use a respirator designed specifically for acid vapors – this is a step up from your typical organic vapor respirator you’d use for spraying lacquer. You really want something stronger that’ll capture those acid vapors.

With the box cleaned off, I started a series of chemical treatments. My main weapons here are vinegar and apple cider vinegar. The cool thing is that these two different types create different shades of rusty colors. Apple cider vinegar actually creates a darker red in the rust patterns. As I apply these, I’m using different spray pattern techniques – each one creates different rust patterns and final colors. I started with a really fine mist, then switched chemicals and did more of a direct spray shot pattern to create more defined areas. I keep changing it up so the finished piece has this modeling effect with different colors and patterns throughout.

Then I grabbed this dead tree carcass to cover the piece, weighing it down to press into the metal. This creates additional patterns and traps moisture so it doesn’t dry too quickly, giving the rust a real chance to bite into the metal. This is a natural rusting process, so there’s no guarantee what kind of colors or patterns you’ll get. It’s really just a matter of guiding it in the direction you want. I had a vision in my head of what I wanted, and I was trying to help it along. Of course, I wasn’t 100% satisfied at first, so I fussed around a bit more to get it closer to my vision.

The Delicate Dance

Working my way around the box was nerve-wracking. The trick is not to screw up what you just finished. I’ve had instances where things get too puddled up on top and run down a side I just completed, making weird streaks and ruining my hard work. So yeah, this was the tense part – trying not to mess it up while still getting cool patterns around the rest of the box.

To seal everything in and preserve my rusty artwork, I sprayed on a conversion varnish.

Adding Weight and Stability

One of the last steps was weighing the base. It’s pretty stable, but it can still tip fairly easily. Once the big piece of glass goes on there with the metal crossbar, someone could potentially push down hard on one side and tip it over. So I stuffed a dust collector bag inside to prevent any concrete from getting on the surface and screwing up my patina work. Then I just poured concrete in to fill it up.

The bag should also prevent the concrete from touching the inside of the box, which could possibly rust it from the inside out. Even though this is an indoor piece and that’s pretty unlikely, I wanted that extra insurance that my creation will last at least my lifetime, if not longer.

When mixing the concrete, I always put about half the water in first. That way, I don’t get any dry spots or clumps stuck to the bottom – it’s just easier to get it mixed thoroughly. Then I add the other half once I get it started, so I can determine how firm or loose I want the mix.

I gave it periodic shakes to spread the concrete out evenly inside, then left it open to dry before tucking the plastic down inside.

Now all that’s left is to take this custom furniture out to Colorado Springs and set up in the client’s house, and set that glass top on it.

More Project Build Videos

Building a Dr. Seuss Inspired Coat Rack

How a straight 4x4 becomes a whimsical, Dr. Seuss-inspired coat rack using a band saw inside-out cutting technique, plus a hand-cut castle joint base.

Building a Fireplace Mantel

In this episode, I designed and built a Craftsman-style fireplace mantel for a client in Colorado Springs.  The mantel was made from hickory and stained to match some of the other millwork in the house.  

Building Modern Contemporary Doors

In this episode, I build a whole house of Modern Contemporary Doors featuring a stainless steel accent for my Colorado Springs client's home.

Asymmetrical Shelf Build

I recently completed an asymmetrical shelf unit for a client, and let me tell you, it was one of those projects that looks simple on the surface but requires serious attention to detail from start to finish.

Installing a Door Lock on a Custom Door

I have installed Door locks of all varieties over the years, from different setback to full mortise locks.  In this episode, I show how to install a door lock and deadbolt set for my custom copper door project.  This was a custom door for a client in Evergreen, Colorado, just outside of Denver.

Building a Nakashima-Inspired Live-Edge Walnut Table

Crafting a live-edge walnut table inspired by the legendary woodworker George Nakashima. The build combines traditional joinery techniques with modern tools, resulting in a piece that balances elegance and functionality. Here’s how I brought this table to life for my Denver Client.

Building a Craftsman Style Bench

I built a Craftsman-style bench with storage.  The design cues for this bench came from my client's Denver home, which was built in the craftsman style.  Specific details I pulled from their home were the rope molding corresponding to the rope bolding in the wainscotting. 

Building a Platform Bed

In this episode, I build a platform bed with a sheepskin headboard for a Colorado Springs Client.  The bed is made from walnut and features four floating shelves attached to the headboard. Each side of the bed has an integrated reading light.

Building a Walnut Vanity with a Live Edge Backspalsh

In this episode, I build a Custom walnut vanity with a live-edge backsplash. This Colorado Springs client wanted a contemporary floating custom vanity with some rustic appeal. To accomplish this, we created a vanity with a beautiful contemporary look and added a live-edge backsplash to give it that Mountain Modern look.  

Custom Wood Inlay on Box Lid

This is a memorial box for a little girl who passed from epilepsy.  Her name is Clair, and the nurses who cared for her called her Clair Bear, so we decided an appropriate inlay was bear.  Each piece of wood was selected for its natural color to tell the story and was inlayed by hand.

Building an Asian Inspired Keepsake Box

In this episode, I build a custom asian inspired keepsake box. The Keepsake box sides are made from bamboo, and the top and legs are cherry. If you are into woodworking and want to make this box, I do have "How To Plans" available for this project.

Building Floating Shelves for a Client’s Master Bath

A client needed a place to display his grandfather's shaving kit and a few other collectibles. Here's how I designed and built the floating shelves to hold them.

Building a Craftsman Style Staircase and Handrail

In this episode, I help a Colorado Springs Client remodel their staircase. The existing staircase was a straight run with an outdated style. I redesigned it to have open-ended steps with a craftsman handrail.

Building a Entry Table With Walnut Cuffs

In this episode, I build a custom entry table with walnut cuffs.  The main table is made from cherry, and the feet are adorned with decorative walnut cuffs.

Learning to Patinate and Bend Metal 

Today's project is more than just building a pendant lamp. I really believe that to continue growing as an artist, you have to always be experimenting, trying new techniques, and working in new mediums.

Building a Scandinavian Round Table

I took my time building this round table. I’m thrilled with the result—a sleek, Scandinavian-inspired table with Midcentury undertones.

Building a Custom Rustic Steel Dining Table Base

Building a custom rustic steel dining table base, from welding and acid treatment to creating unique rust patinas with vinegar and finishing with weighted concrete for stability

Making a Wooden Ice Bucket

Today's project is to build a decorative wooden ice bucket for a bar cart I constructed earlier. This isn't a functional piece meant to hold water; it's a prop, designed solely to add visual interest and character to my home bar setup.

Building a Sculpture that Doubles as a Coat Rack

building a sculptural two-moon coat rack, from grain-matched bandsaw cuts and CNC joinery fixtures to hand-shaped hooks and a hidden wall-mount system.

DIY Barn Door Guide

A while ago, I built a barn door with a steel frame that encased the wood for a client in Denver, Colorado. It turned out great, but one question kept coming up: How did I keep the bottom of the door from swinging around? Most barn door hardware kits include a T-track that gets screwed into the floor, with a slot routed into the bottom of the door for guidance. But since my door had a steel base, routing a groove wasn’t an option.

Dining Tables

Big Leaf Maple Slab Dining Table

Scandinavian Modern Round Dining Table

Glass Dining Table with Steel Patinated Base

Dining Tables at Red Rocks

Red Rocks Artisan Dining Tables

Two Tone Trestle Dining Table