Making outdoor furniture from wooden pallets can be a fun and rewarding DIY project. Pallet furniture is inexpensive, customizable, and adds a rustic, industrial vibe to your patio, deck, or yard. With a few basic tools and materials, you can upcycle used wooden pallets into beautiful chairs, tables, sofa beds, and more for your outdoor space. We will walk you through the entire process step-by-step, from sourcing and preparing pallets, choosing furniture designs, sanding and staining, to assembling your finished pallet creations. Follow along to learn how to build stylish and sturdy outdoor furniture from pallets!
Sourcing and Preparing Pallets
The first step is finding and selecting quality wooden pallets to work with. Here are some tips:
- Check construction sites, factories, warehouses, shipping centers, superstores etc. They often have extra wooden pallets they are looking to get rid of. Ask politely if you can take some off their hands.
- Inspect pallets carefully before taking them. Look for intact, undamaged wood with no loose boards, nails, or rot. Avoid pallets with chemicals/oil stains.
- Aim for sturdier pallets made of hardwood like oak. Softer woods like pine can work but may be less durable. Standard pallet sizes are 48″x40″.
- Take apart pallets using a pry bar, hammer, and pliers. Remove all boards and set useable ones aside.
- Pull out all nails from boards using pliers or a claw hammer. Watch for stray nails left in boards.
- Wipe each board with a damp cloth. Let air dry completely before using.
- Cut boards to needed lengths using a handsaw, jigsaw, or miter saw. Trim off jagged edges.
- Sand boards using 80-100 grit sandpaper to smooth rough spots. Wear a dust mask when sanding.
Thoroughly preparing pallet wood is key for building attractive and sturdy furniture that lasts.
Choosing Furniture Designs
Now for the fun part – picking furniture projects to build! Here are some popular options perfect for the patio or yard:
Patio Sofa Pallet Bed
This comfortable patio sofa easily converts into a bed. Build a base from 2x4s and pallets for supports. Use pallet wood for the arms, back, seat, and kickboard. Add cushions for comfort. Sturdy and space-saving!
Pallet Coffee Table
Pallets stacked in different configurations make excellent coffee tables. Use 2-3 pallets with varying height for the base. Add a pallet board on top cut to size. Stain, seal, and add hairpin legs. Customizable and industrial-chic!
Pallet Lounge Chairs
Lounge chairs are perfect for relaxing outdoors. Use 3 board widths to form the seat at an angle. Cut 2 pallet pieces for the legs and nail into place. Add a backrest and armrests with pallet wood. Finish with cushions or pillows.
Pallet Bars
Build your own backyard bar from pallets! Use 2 pallets upright at right angles for the sides. Place a pallet board across the top and add trim. Include pallet shelving, bottle racks, and hooks. Stain and add barstools. Cheers!
Pallet Planter Boxes
Decorate your patio with pallet planter boxes! Use full pallet sections or single boards. Add drainage holes and line with landscape fabric before filling with potting soil and plants. Paint fun colors and get creative.
Consider your space, skill level, and budget when selecting DIY pallet projects. The possibilities are endless!
Sanding and Staining Pallet Wood
Before assembling your furniture, it’s important to properly sand and finish the pallet boards. Here are some tips:
Sanding
- Use an orbital sander with 80, 120, and 220 grit sandpaper for smooth wood. Hand sand hard to reach spots.
- Always sand in the direction of the wood grain. Go over entire board until smooth.
- Wear a dust mask when sanding to avoid inhaling particles. Work outside or use a shop vac.
- Sand boards until splinters are removed and wood feels smooth. Pallet wood has rough areas that need attention.
- Rounded edges and light distressing add charm. Avoid rounding over corners too much.
- Sand lightly between coats of stain or sealer for best results.
Staining
- Choose oil-based stains for best absorption and rich color on pallet wood. Test colors on scrap wood first.
- Wipe on stain using a clean cloth. Apply evenly with the wood grain in thin coats.
- Let stain penetrate 15 mins before wiping off excess. Allow 2 hours drying time per coat.
- Consider a weatherproofing stain for outdoor furniture. This protects from UV rays and water damage.
- Apply 2-3 coats of stain for best coverage and color intensity. Lightly sand between coats with 220 grit paper.
- Top with a polyurethane sealer for added protection and sheen. Use a brush on spar urethane for outdoor projects.
Proper sanding and staining helps pallet wood resist weathering and lasts longer when used outdoors.
Assembling Pallet Furniture
You’re almost ready to enjoy your custom pallet furniture! Follow these final steps:
Use Exterior Grade Hardware
- Outdoor conditions require corrosion-resistant hardware. Use galvanized or stainless steel nails, screws, and bolts.
- Pre-drill holes when screwing pallet boards together to prevent splitting. Countersink holes for a flush finish.
Reinforce Weight Bearing Points
- Add wood glue before nailing or screwing joints for added strength. Allow to fully cure overnight.
- Use corner brackets or build additional supports at high stress points. This prevents damage over time.
- Place heavy items like concrete pavers on pallet coffee table bases for stability.
Weatherproof for Longevity
- Seal all sides of furniture even if they won’t be visible. This prevents moisture damage.
- Consider adding a plastic or metal wrap on legs touching damp surfaces so wood won’t rot.
- Use water-resistant glue when attaching cushions or fabric to repel rain and sprinklers.
- Inspect furniture every few months. Touch up stain on fading spots and replace rusted hardware as needed.
Take time assembling so your furniture lasts for seasons to come! Add cushions, storage bins, and decor for the final touches. Create a comfy and eye-catching space to relax in your own backyard oasis!
Helpful Tips and Inspiration
Building functional DIY furniture from used pallets takes a bit of work, but the results are rewarding. Keep these last tips in mind:
- Draw out furniture plans tovisualize the design and how pallets will be used. Make adjustments before cutting.
- Gather all materials – pallets, hardware, tools, stain, cushions etc. Having everything ready makes the process smoother.
- Wear safety gear like gloves and goggles when deconstructing pallets and sanding. Loose nails and wood fragments can cause injury if not careful.
- Work on a flat, spacious surface like a driveway or under a patio cover. This provides room to cut and assemble.
- Set concrete pavers or bricks under pallet furniture to prevent rotting and sinking into the ground over time.
- Check out online DIY pallet furniture guides if you need guidance for more complex builds. Many include useful schematics and instructions.
- Add weatherproof outdoor cushions in complementing colors for comfort and style. Waterproof canvas or polyester are good outdoor fabrics.
- Incorporate fun decor like outdoor curtains, accent lighting, planter boxes, and patio rugs to make the space inviting. Get creative!
Upcycling pallets into patio furniture is inexpensive, eco-friendly, and lets you build exactly what you need. We hope these tips help you create beautiful backyard pieces your whole family can enjoy for years to come!
Frequently Asked Questions About Making Pallet Furniture
What type of wood pallets are best for outdoor furniture?
Hardwood pallets made of oak, maple, or ash are best, as they are sturdier and more weather-resistant. Avoid using softwood pallets with excessive knots or damage. Also inspect pallets to ensure no exposure to chemicals or treatment.
How do I flatten warped pallet boards?
You can flatten slightly warped boards using clamps or extra weight to keep them pressed overnight. For severely warped planks, cut off the warped portion and use the stable wood only. Prevent warping when sanding by keeping an even surface.
What hardware should be used for outdoor pallet projects?
Opt for galvanized steel or stainless steel nails, screws, bolts etc. These will not rust or corrode like standard hardware. Pre-drill holes for screws to avoid splitting wood.
Should pallet furniture be sealed or stained?
Yes, it is highly recommended to seal and stain pallet furniture, especially for outdoor use. Look for weatherproofing wood stains and apply a polyurethane sealer to protect from moisture damage and UV rays.
How do I deter pests from eating my pallet furniture?
Insects like termites are attracted to the sugars in untreated wood. Use a non-toxic insect repellent made for wood furniture or coat pallets with food-grade diatomaceous earth before building. Reapply annually.
Can pallet furniture last outdoors year-round?
Yes, as long as quality, weatherproofed pallets are used and furniture is properly assembled and maintained. Place pallets under furniture to prevent wet ground rot. Bring cushions/pillows indoors when not in use.
How can I make pallet furniture more comfortable?
Add outdoor cushions, pillow backs, padded seat covers, and lumbar supports. Look for weather resistant cushion fillings like closed cell foam, polyfill or recycled plastic beads. Include waterproof outer fabric.
What if I need help with my pallet furniture project?
There are many online DIY pallet building guides with detailed instructions and schematics if you get stuck. Watch pallet furniture videos as well. Seek help from experienced carpenter friends. Start small and work your way up.
Conclusion
Upcycling pallets is a smart, eco-friendly way to build furniture exactly how you want it. We hope this guide offered helpful tips for successfully planning your own pallet furniture projects. From sourcing quality pallets to sanding, staining, and assembling them into enduring patio furniture or backyard accessories, you can create beautiful designs on a budget. Just be sure to use weather treated pallets, properly seal and reinforce furniture, and add cushions for comfort. In no time you’ll be lounging outdoors in your own customized oasis – all thanks to humble wooden pallets!