One thing I’ve always wanted to try was making a chair out of pallets. It may seem silly to some, but for me it was a bucket list goal. So here are the steps I took to check that off the list.
Pallets:
You are going to need at least two of these. Used are best but you can get them from home improvement stores if you want. You want to make sure they are in good condition as this will be beneficial in the long run.
Tools:
Of course we need tools! Below is a list of what you will actually need for this project.
Nails
Hammer
Screws
Screwdriver
Wood Cutter
Drill
Sanding Sheets or a Belt Sander
Cutting:
Now that we have the pallets and tools, it is time to cut. Start by cutting one of the pallets in half. Be sure to cut along the center support. You also need to measure and make sure they are the exact length you want them to be. Nothing is worse (I found out the hard way) than them being a few inches different. Check your halves and make sure they are both sturdy. One will be the back support and the other will be the part you sit on.
Next cut the second pallet in half. Again, cut long the center support. This will be the two sides of the chair.
Sanding:
Now that you have cut your pallets and measured them to your liking, it is time to sand them. Sanding is important for two reasons: one it makes the surface smooth and two cuts down on splinters. The last thing you want to do is sit in your new chair and get a splinter.
You have two options for sanding. You can sand the pieces down with sandpaper by hand or use a sanding belt. I prefer the latter because for me, sanding my hand worked out muscles I didn’t even know existed. The choice is up to you and is whichever you prefer. There is no right or wrong answer as to the two choices.
Assembly:
You are now ready to screw the back of the chair to the base. Some people I have seen prefer to place an extra piece of wood inside the pallet that is used for the back. This allows for extra support. I recommend this, but it isn’t necessary.
Once you attach those pieces you are ready to attach the sides. This is done by screwing the pallet pieces to the sides of the base and back of the chair. Now you can nail the sides and the base/back. The nails will provide extra support for the pallets to hold the weight of whomever sits in it.
Stain:
A stain is completely optional. You can leave the chair as it is or apply a water-based wood stain to it. If you choose the stain be sure to let it dry completely (another mistake I learned from!) before testing it out. I left mine for 48 hours that way I knew it was completely dry.
If you are new to working with pallets I would suggest allowing yourself a few days to work on this project. If not, you should be able to complete it in a few hours.