Looking to upgrade your sofa but don’t have a big budget? Save money by making your own DIY Pallet Sofa with this handy tutorial! See for yourself how to turn old pallets into your own personalised and comfy sofa, a perfect match with your living room or garden!

DIY Pallet Sofa Tutorial

thehandymano mano DIY pallet sofa tutorial finished

Tools and materials

thehandymano mano DIY pallet sofa tutorial tools and materials

The tools and materials that you’ll need to make this DIY pallet sofa are as follows:

Cost, time and difficulty

This project is rated medium difficulty as it requires a certain level of skill when it comes to handling the electric tools. If you use manual tools to cut and dismantle the pallet, it will be easier.

The approximate price of the materials is around £100, if you already have the tools needed to make the sofa. This biggest expense is mainly for the cushioning for the sofa seat and backrest, meaning it will be reduced if you use something you already have! You can find the other tools in this suggested basket here.

On another note, to make this sofa from pallets as per the tutorial, you will need a couple of days work to complete everything, including assembly and varnishing. This time may even increase if you use manual tools, or pallets in a particularly bad condition. The more deteriorated these are, the longer it will take you to get them fit for purpose.

How to make a DIY Pallet Sofa

Step 1: Cut the pallet to the size of your cushions

This first step is important if the pallet you have found or bought doesn’t match the size of the seat and backrest cushions. You won’t need to do this if you’re using custom-made cushions.

In our specific case, the pallets measured 120 x 100cm, so we cut the one for the base to fit the size of our cushions. To do this, we followed these steps:

  1. Mark the size the pallet will be cut to.
  2. Cut the pallet slightly bigger using the reciprocating saw.
  3. With a circular saw, cut the pallet’s crossbeam to the desired size.
  4. Screw the extra boards that you cut in step 2 to the edges of the pallet, as well as to the front and back.

thehandymano mano DIY pallet sofa tutorial prepare wood

Step 2: Dismantle the pallet

The next step is to dismantle the pallet using the reciprocating saw or the  crowbar or lever (the first option will be quicker than the second)

thehandymano mano DIY pallet sofa tutorial dismantle wood

Step 3: Sand and plane the pallet and boards

Next, sand the pallet using an orbital sander. This type of sander is the most suitable when it comes to sanding pallets, as its rectangular shape is ideal for the boards that make up the pallet.

However, if the wood is very rough or has many imperfections, it will be a good idea to use a plane instead. This allows you to file down the boards, and after a couple of strokes with the plane, the wood will be completely smooth and flat.

It’s extremely important that before you use the plane, you remove all nails that may remain in the boards, to avoid damaging the plane’s blade.

thehandymano mano DIY pallet sofa tutorial orbital sander

Step 4: Cut boards for the legs, back and armrests

Once you have sanded all the boards, use the mitre saw to cut them as the legs, back and armrests. The sizes are as follows:

  • Use cross beams from the pallet to make the legs as these are the sturdiest and strongest. You will need 4 measuring 50cm long.
  • 2 pallet boards measuring 84cm will be joined to the top of the legs as armrests.
  • 3 pallet boards measuring 75cm long will be screwed to the back of the pallet. You will use two more boards measuring 120cm long to complete the backrest.

thehandymano mano DIY pallet sofa tutorial mitre saw

Step 5: Varnish the parts

Before assembling the legs and backrest, varnish both the pallet and the loose boards. In this way you can more easily reach all the nooks and crannies, because once everything has been assembled, it will be a lot more complicated.

For this, you should use an oak stained varnish. Not only does this help to protect the wood but it also adds a nice touch of colour.

thehandymano mano DIY pallet sofa tutorial varnish

Step 6: Assemble the legs, backrest and armrests

Once the varnish has dried, assemble the various parts of the sofa

  1. Legs: screw the cross beams using a couple of coach screws to the 4 edges of the pallet. To ensure all of the legs are the same length, and the sofa isn’t crooked, we used a block of wood as a guide.
  2. Backrest: screw the 3 boards measuring 75cm to the back of the pallet. The ones for the sides should be screwed to the legs too.
  3. Armrests: attach a board measuring 84cm long to each side, joining the top to the legs.

thehandymano mano DIY pallet sofa tutorial assemble back rest

En la siguiente imagen se puede ver el resultado final una vez se hayan montado todas las piezas.

thehandymano mano DIY pallet sofa tutorial complete no cushions

Step 7: Add the cushions

Fnally, add the cushions to finish the transformation of a pallet into you very own DIY pallet sofa! Note that the cushions we used for the backrest have ties at the rear to allow you to attach them to the wooden slats.

thehandymano mano DIY pallet sofa tutorial add cushions

thehandymano mano DIY pallet sofa tutorial finished project

This article was written by: Bricoydeco and translated. Mari Luz authors the blog ‘Bricoydeco’, she is a DIY fanatic, lover of recycling and customising furniture. Her passion is giving a second chance to turn once forgotten things into unique pieces!

If you enjoyed making your own DIY pallet sofa, why not have a look at our other pallet DIY tutorials?

Pallet TV Stand DIY Tutorial

Pallet Table DIY Tutorial

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