When you want to add a unique and on-trend piece of garden furniture to your patio, why not have a go at making this upcycled pallet chair? It uses just four used pallets to create a two-person garden bench. The cushioned base and back is made using a sun lounger pad, so you can be sure it’ll be comfy for lounging in your garden all summer long.
What you’ll need
To do this DIY project you’ll need the following tools:
In addition, these materials will be needed:
4 x Pallets (these are 1200 x 800mm) – find out how to find cheap or free pallets
Assorted sandpaper to fit your palm sander in course, medium and fine grit
10 x M6 bolts with nuts 50mm
4 x castor wheels with break
16 x screws
Cost, time and difficulty
The approximate cost of materials for this project is £45. You can access the shopping cart of some of the tools and materials used through this link.
This project is quite simple and is therefore suitable for beginners. Depending on your DIY skills, this project shouldn’t take longer than 3 hours to complete.
Step 1: Cutting out the pallets
Use a set square to draw straight lines across the sides of the pallet, alongside the internal blocks, as a cutting guide. Use a jigsaw to cut along these lines on the top and underside of the pallet. This will create ‘arms’ on sides of the pallet. You’ll need to make one more cut with a hand saw across the back of the pallet to separate the middle section from the arms and back, leaving one full plank as a back rest. Repeat this step to create a second arm frame from a second pallet.
Step 2: Sand the pallets smooth
Sand down all the rough edges of the arm frames until you have a smooth, driftwood-like finish. Use an electric sander to speed up the process. If you need to get between the gaps of the pallets, use a piece of sandpaper to manually smooth down the surface. Sand down the whole top surface of one solid pallet to form the seat layer, and around the edges of the second base pallet. Make sure these solid pallets are well sanded on the front, as this is where legs will come into contact with the wood.
Step 3: Drill pilot holes for the bolts
Measure and pilot drill some holes for the bolts to hold the chair frame together. Use a drill bit 1mm larger than the bolts you’re using to make it easier to thread them through. Add four holes across the front of the two base pallets where they will meet when stacked together. Drill two holes in the back of the base pallets and two in the back of each of the arm frames. When you stack them up, the pilot holes should line up, but don’t bolt them together yet.
Step 4: Attach caster wheels
Turn the base pallet over and attach castor wheels to each of the four corners, using long screws. Put this pallet flat on the ground and stack the second pallet on top. Bolt together at the front and back, using a spanner to tighten the nuts and bolts.
Step 5: Glue the arms together
Stack the arm frame onto the pallets and cover underside of the front arm block with wood glue to attach it to the base. Line up and bolt the pilot holes together at the back. Repeat with the second arm frame, adding wood glue at the front and bolts at the back.
Step 6: Create a comfy cushion
Depending on the size of your pallets you may need to find a suitable sized sun lounger pad or bench cushion for the pallet chair seat you’ve created. In this instance, the sun lounger pad needed to be cut in half and the loose edges stitched back together. You can hand stitch or use a sewing machine to neaten the edges or leave them raw. Use one half on the base of the pallet chair and the other half at the back.
We hoped you enjoyed this article about how to make an outdoor chair from pallets! If you give it a go, be sure to let us know.
This article was written by Cassie Fairy. You can find Cassie’s blog ‘My Thrifty Life’ at Cassiefairy.com, where she shares daily blog posts about her home DIY projects, upcycled finds, budget recipes and plenty of inspiration for living a low-cost yet lovely life.
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