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Pallet projects are a lot of fun, and best of all they are affordable. Pallets can often be acquired
for free or very cheap from local warehouses or hardware stores.
Pallets also provide a “rustic” look to your project, since every board has character and is
unique. Before we share 3 of our favorite DIY pallet projects you can do this weekend, here
are some steps for disassembling your pallets (which can be really difficult if you try to pry
them.)
Take apart your pallet by cutting it.
This is my preferred method because it is faster than any other method I have attempted.
Most of my pallet projects are not so fancy that I care about nails in the wood or maintaining the
“original” length of the boards. You could say that I have low standards for accuracy…
My low standards afford me the luxury of spending about 5 minutes dismantling each
pallet…and without much effort.
Here is how it’s done.
1. CUT EXCESS WOOD FROM SIDES
I find it easier to cut the wood away that is hanging over the side of the pallet, but it isn’t
necessary. Depending on the project, you may need the boards at their full length.
Likewise, you may want the boards smaller. In this case, cut along the runners and remove the
small pieces of wood still attached by the nails afterwards.
2. CUT NAILS WITH SAWZAW
Make sure you have a metal blade attached to the sawzaw, and one long enough to cut both
nails at the same time.
Sometimes it can be difficult to get the blade between the boards, but if you press the trigger
slightly, the reciprocating blade will slowly work its way to the nails.
3. REMOVE NAILS FROM CUT BOARDS
Use a punch to hit the nail through the board.
Need more instruction? Watch the full video on Youtube from beachbumlivin.
Project #1: Pallet Feature Wall
Creating an accent wall out of reclaimed pallet wood is such a simple and cheap project!
It also looks amazing, and will be sure to have your guests talking.
Here is a step by step tutorial on how you can create this on virtually any wall of your house:
What You’ll Need
Pallets (number depends on size of wall)
Pallet buster (to disassemble pallet boards)
Miter Saw (this one works well)
Pencil
Level
Liquid Nails
Ready to get started?
1. MEASURE THE WALL
This will give you an idea about how many planks you’ll need, which also lets you decide how
many pallets it will take. It’s hard to estimate since every pallet is different, and has a different
amount of planks on it.
There are tons of things you can do with pallets, so it never hurts to get too many!
If it helps, dividing the length + width of your surface and dividing by 144 will give you the total
amount of square feet you’ll need. It takes about 7 or 8 pallet boards to get 10 square feet.
2. PREPARE SURFACE
Clean the wall with some soap and water, and make sure to pull out any nails or items that may
cause an issue when you hang the boards.
3. DETERMINE A PATTERN
We’re going to do a staggered horizontal design, but if you are going to align your boards
differently, now is the time to decide.
4. DRAW A REFERENCE LINE
Using your level and pencil, draw a straight line across the area where you’ll be laying the
boards. This will be your starting point and make sure that your first boards are completely level
and straight, so the wall doesn’t get crooked!
5. ADD PLANKS ON REFERENCE LINE
Using your liquid nails (or other construction adhesive) apply a liberal amount to the back of
your first board. Place the first board directly above or below your reference line and press it
onto the wall. Make sure this plank is level. Then, apply a second board on the other side of the
reference line – staggering the boards as shown below.
6. FILL IN THE ENTIRE SPACE
Using a miter saw to cut/trim boards as needed, fill in the entire space staring with the boards
along the reference line. Simply repeat the steps over and over until your project is complete.
Now you’re done!
Enjoy your pallet wall for years to come!
This project comes to us from Wabash Lumber, check out the full video below or click here to
watch it in action.
Project #2 - Rustic Wall Shelf
Today we’re going to show a step by step guide to building a cool wall shelf out of pallets. Pallet
projects are hot right now, and this shelf in particular has a very rustic look that will be sure to
have your guests talking.
If you need some help finding free pallets and reclaimed wood for your projects, check out this
article.
This tutorial comes from Jake Schmanke, and here is a look at the finished product:
WHAT YOU’LL NEED:
Four 36 inch pallet boards
Two thicker pieces of reclaimed wood to use as shelves
One rustic/vintage hook
One thin (1 inch) board to brace the back of the shelf
Tape measure here’s the one I like.)
Compound miter saw (Here’s our top rated miter saw)
Pencil for marking measurements
Eight 1 inch screws
Four 2.5 inch screws
3/32 drill bit
STEP BY STEP GUIDE:
STEP 1: CUT THE 4 PALLET BOARDS TO 36 INCHES.
While you may or may not want the boards to be exactly even – you want to start by making
them all about 36 inches long. Simply mark the measurements with your pencil, then use your
miter saw to make the cuts:
STEP 2: MEASURE AND MARK SHELVES
For the bottom shelf, the design shown only used about 7 inches of shelf. So measure one of
your shelves to 7 inches and then cut it. For the top shelf, this design makes it an 11 inch shelf.
So cut your second shelf to 11 inches:
STEP 3: CUT THE SHELVES
While these shelves are 7 inches wide and 11 inches wide, respectively; you could technically
make them as long or as short as you’d like, depending on what you plan to hang on them.
STEP 4: MARK AND CUT THE BRACES
Take your one inch scrap board and mark it with a pencil so you can get 2 pieces out of it. As
shown below, these 2 pieces are going to be on the back of your shelf and serve as a brace, to
make it more stable. In this case, simply mark your scrap board so it is a little less than the width
of your shelf. Once you’ve marked it, cut your 1 inch board so you get 2 back braces out of it.
STEP 5: FLIP YOUR PALLET BOARDS OVER AND ATTACH THE BRACES
Once you’ve flipped the boards so you are now working on what will be the backside of your
shelf, simply put your braces in place and attach them with one inch screws, using at least 3
screws spaced throughout your brace. (Note: places your braces where you plan to put your
shelves, as the braces will provide extra support and give you more wood to screw into when
you attach the shelves.)
STEP 6: LEVEL AND MARK YOUR SHELVES
Using a small level and your pencil, put your shelves in place on the front of your shelving unit.
Remember that your shelves should be directly on top of the braces you attached to the back,
so they have extra support. Mark a line on both sides, so you can see where your shelf will be
attached.
STEP 7: PREDRILL YOUR HOLES
Flip the shelf on it’s side, and hold your shelf into place firmly – using your pencil marks to make
sure you are holding it level and in place. Then, use your drill bit to drill straight through your
brace, the shelf back, and the shelving board. Predrilling your holes will make putting the
screws in a whole lot easier!
STEP 8: SCREW IN ONE SIDE OF THE SHELF
After you’ve drilled the pilot hole, put one of your 2 1/2 inch screws into that hole, which will
attach one side of your shelf.
STEP 9: LEVEL THE SHELF BEFORE PUTTING IN YOUR SECOND SCREW
By only putting in your first screw, this gives you a chance to pull out a small level and make
sure your shelf is perfectly straight, before putting in your second and final 2 1/2 inch screw.
Once it’s confirmed to be level, repeat step 8 on the other side of the shelf, drilling a pilot hole
and putting in your second screw.
STEP 10: REPEAT FOR SHELF #2
Attach your second shelf following the same steps that you used for the first one – remember
that drilling pilot holes will make putting your screws in much easier.
STEP 11: ATTACH YOUR RUSTIC HOOK
One reason for leaving the shelves a little more narrow in this design is so you can add a rustic
looking hook to hang a hat, jacket, etc. next to your shelves. If you have one, find a vintage
looking hook and simply attach it with a 1 inch screw.
You’re done!
To watch Jake’s video tutorial to making this shelf, click here.
Project #3 - Chevron Pattern Coffee Table
The Saw Guy here with another pallet project. This coffee table from pallets isn’t just your
typical coffee table. Using the “chevron” pattern, this pallet coffee table from Beach Bum Livin is
one of the coolest yet, but also, one of the easiest.
Get your short list of tools ready. Here we go!
WHAT YOU’LL NEED
Drill
Power Planer (not 100% necessary)
Table Saw and Circular Saw (can be done with circular saw only)
Sawzaw (I recommend this one)
Nail Gun
Kreg (pocket hole) Jig
Hammer and Nails
23 in Deck Screws
At least 4 pallets
2×4 – 1/2 inch Sheet of Plywood
8 ft – 4×4
2 8 ft – 1×2
1. DISASSEMBLE PALLETS
Everyone has a favorite (very relative term) way to dismantle pallets. However, if you’re not
familiar with the process, or are looking for tips, click the link below to check out our guide.
2. CUT EACH PLANK TO 21/2 INCHES
The table will fit more planks to makeup the table top if each board is cut down to 21/2 inches.
It also ensures a straight edge on each board, helping each plank to fit tightly against one
another.
The tutorial shows each board being planed before assembly. This will help the grain to stand
out, but isn’t entirely necessary. However, if you do not plane the boards, I suggest sanding a
little to clean the wood up (which also helps expose the wood grain).
3. MAKE 45 DEGREE ANGLES
Cut one end of each of the 21/2 inch boards at a 45 degree angle. If you have a table saw or
amiter saw, this is the best time to use it. However, if all you have is a circular saw, just make
sure to mark the 45 degree angle with a bevel.
4. ASSEMBLE CUT WOOD PLANKS & ATTACH TO BASE
I recommend lining up all of your pieces (45 degree angle inside) to ensure you have enough,
and so that you don’t get into a situation where you have to disassemble everything.
Draw a straight line down the center of the plywood.
Once you’re confident in your design, start attaching each board onto the plywood by adding a
layer of wood glue. Next, use a nail gun (or hammer and finish nails) attaching the board onto
the plywood.
5. CUT AWAY EXCESS PLANKS
Using your circular saw, cut away the excess wood on each side of your tabletop.
6. ATTACH 1×2 FRAME
Basically, you want to border the tabletop with 1×2’s to cover up the edges.
7. ATTACH LEGS
Use the base pieces from your disassembled pallets, cut, and attach to the underside of your
tabletop.
If you have a Kreg Jig, awesome, use it. If not, go back to step 3 and screw your plywood base
into the pallet base pieces before you attach the tabletop wood.
Now, just screw your 4×4’s into the pallet base pieces.
8. FINISHING TOUCHES
Dude…you’re basically done! The finishing touches are all up to you. If you want a smooth
finish, sand it up. Stain it or something. Try painting it with some chalk paint…it’s up to you.
Watch the full tutorial from Beach Bum Livin here.
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