Hello, my dear Upcyclers!
I’ve finally managed to make another pallet project. Yay!!! It’s taken me much to long and I promise you won’t have to wait that long for the next one 🙂
So in this post, I’d like to show you how to build a pallet coffee table from just only one pallet plus some scrap pallet wood and blocks.
Tools and Materials
- a circular saw
- a hand saw
- a random orbital sander and different grit sandpaper (40,60 ,80, 120, 150)
- a hammer
- nails, and wood screws (I used single thread 12 x 4″ wood screws)
- a pencil
- a wood glue
- some rags/cloths for wiping
- paint brushes
- a wood stain and top coat
- a measuring tape
Step 1 – Choosing a Pallet
I chose a pallet that was medium weight and had wide planks. The idea is to use whatever you’ve got to fit the project. This pallet was pretty much square and was roughly 4’x 4′ (1.2 x 1.2m). The coffee table I wanted was going to be 1.6’x 4′(0.55x 1.2m) so it fitted perfectly. All I had to do was cut it in half.
So I thought…
Step 2 – Cutting to size
Because of the pallet size, I was planning to cut the middle plank out altogether with wooden blocks underneath (as shown in the picture above) . This way I’d had 2 roughly the same size parts that I’d stack up to make the table.
I didn’t want to move any planks because the nails used were very difficult to remove. This way I didn’t have to. The only thing I had to do is to detach the wooden blocks that were nailed to this plank. I was going to use them later on.
That was the only problem I came across – detaching the blocks. In the end, 2 out of 3 split and I had to use something else.
Step 3 – Sanding
To sand the wood I used a random orbital sander with 40 grit sandpaper to start. I wanted to remove as much material as i could. Then I moved to grit 60 and 80.
I also attached the missing wooden blocks.
The pictures below show results after sanding and before staining.
The left part was going to be a top and the right the bottom.
Step 4 – Staining
Now the parts were ready to stain. I didn’t have a regular stain that you apply with a cloth and wipe the excess. Funnily I didn’ realize that and used the varnish/stain as a regular one. So after wiping there was barely anything left on the wood.
My excuse was that my brother was helping me with that and he didn’t read the label. The result was poor and that only meant I had to use more of this stain and apply it with a paintbrush.
The plus side is that it has a lovely glossy finish and it’s waterproof. Not the outside-left-in-the-rain-proof but good enough for water/drinks spillages.
I applied 3-4 coats altogether sanding with 120 grit in between coats. My sander was a bit too powerful even on slow speed so I did it mostly by hand. I didn’t want to sand trough the stain. Before the last coat, I used grit 150 to smooth the top surface.
This table is not “perfect”. It’s not meant to be. I wanted it to have a character you get when using used pallets.
At the end, all that was left was to stack the 2 parts on top on one another and join them together. The simplest solution is to glue them and I used simple door hinges (I haven’t received them yet so you won’t see them here) to make it more secure.
The Final Result
Do you like it? You’re more than welcome to leave a comment below and tell me what you think. For more ideas on Pallet Coffee Tables check my Inspiration Section.