DIY Bench Made from Pallet Wood – A Step‑by‑Step Guide
If you’ve ever walked past a stack of abandoned pallets and imagined turning that rough‑sawn timber into a piece of functional art, you’re not alone. Pallet wood is cheap, abundant, and surprisingly sturdy—perfect for a rustic garden bench, a porch seat, or a bedside perch. In this post you’ll learn exactly how to transform a handful of pallets into a beautiful, durable bench while staying on a tight budget.
Quick‑look summary – Grab the table below if you only need the essentials.
| Item | Approx. Cost* | Where to Source | Key Tips |
|---|---|---|---|
| 2 standard 48”×40” pallets (for a 4‑ft bench) | $0–$15 (free‑pick‑up) | Home improvement stores, warehouse loading docks, Craigslist | Look for pallets stamped HT (heat‑treated) – they’re safe for indoor use. Avoid MB (methyl‑bromide) treated pallets. |
| Circular saw or hand saw | $0 (borrow) – $120 (buy) | Tool library, friend’s garage | A fine‑tooth blade reduces splintering. |
| Power drill + 1/4” drill bit | $0 (borrow) – $80 | Same as above | Use a drill with variable speed for clean pilot holes. |
| Deck screws (2½” – 3”) | $5 (1‑lb box) | Hardware store | Stainless steel resists rust in outdoor settings. |
| Sandpaper (80, 120, 220 grits) or orbital sander | $5–$30 | Home depot | Finish with 220 for a smooth, splinter‑free surface. |
| Wood finish (oil, polyurethane, or exterior paint) | $10–$25 | Paint store | Oil penetrates deep; polyurethane protects the surface. |
| Optional: Wood glue, clamps, metal brackets | $5–$15 | Hardware store | Glue adds extra strength for the seat slats. |
| Total (typical) | $20–$70 | — | Depends on tools you already own. |
* Prices are US‑based averages (2025).
1. Why Pallet Wood?
| Advantage | Reason |
|---|---|
| Low cost | Many pallets are discarded for free. |
| Eco‑friendly | Upcycling prevents waste and reduces demand for new lumber. |
| Rustic appeal | The weathered grain gives a natural, industrial look. |
| Strength | Pallet boards are usually made from hardwoods (oak, pine, spruce). |
| Availability | You can find pallets in almost every city. |
2. Planning Your Bench
2.1 Choose a Size
A comfortable bench seat is typically 16–18 inches tall, 12–14 inches deep, and 36–48 inches long. Adjust dimensions based on where you’ll place it.
2.2 Sketch a Simple Blueprint
| Part | Dimensions (inches) | Quantity |
|---|---|---|
| Legs | 16 h × 4 w × 4 d | 4 |
| Seat frame (front & back) | 48 l × 4 w × 4 d | 2 |
| Seat frame (sides) | 16 l × 4 w × 4 d | 2 |
| Seat slats | 48 l × 2 w × 1 d | 8‑10 (spaced 1‑1.5 in apart) |
| Cross‑support (optional) | 12 l × 4 w × 4 d | 2 |
All measurements are guides – feel free to tweak them.
3. Tools & Materials Checklist
| Tool | Purpose | Recommended Brand / Model |
|---|---|---|
| Circular saw or handsaw | Cutting pallet boards to length | DeWalt 15‑A 7‑1/4” Circular Saw |
| Power drill with screwdriver bits | Driving screws, pre‑drilling pilot holes | Makita 18 V LXT |
| Orbital sander (optional) | Smoothing surfaces quickly | Bosch ROS20VSC |
| Safety gear (gloves, goggles, dust mask) | Protection from splinters & dust | 3M Respirator 6200 |
| Tape measure & carpenter’s square | Accurate measurements & right angles | Stanley 33‑425 |
| Clamps (optional) | Holding joints while the glue dries | Irwin Quick‑Grip |
4. Step‑by‑Step Build Guide
Step 1 – Harvest & Inspect Pallets
- Select pallets that are in good condition (no broken boards, minimal rot).
- Identify the stamp:
HT(heat‑treated) is safe,MB(methyl bromide) is not recommended for indoor projects. - Remove nails with a pry bar, hammer, or a nail puller. Work slowly to avoid splintering the wood.
Step 2 – Disassemble & Clean
Tip: Lay the pallet flat and work from the inside out.
| Action | Detail |
|---|---|
| Strip the deck boards | Use a reciprocating saw or a crowbar. |
| Remove the base stringers | These become great support beams for the bench frame. |
| Sand the rough edges | A 80‑grit paper removes splinters. |
Step 3 – Cut to Size
- Cut the legs to the desired height (usually 16 in).
- Cut the frame pieces according to the dimensions in the blueprint.
- Rip the seat slats to a uniform width (≈2 in).
Safety note: Always wear eye protection and a dust mask when cutting.
Step 4 – Assemble the Frame
- Lay out the rectangle (front, back, and side rails).
- Pre‑drill pilot holes ⅜” from each edge to prevent wood split.
- Attach with 2½” deck screws (or 3” for extra grip). Tighten until the joint is flush.
| Joint | Screw count | Recommended screw length |
|---|---|---|
| Leg to side rail | 2 per leg | 2½ in |
| Side rail to front/back rail | 2 per intersection | 2½ in |
| Cross‑support to legs | 2 per leg | 2½ in |
Step 5 – Add Seat Slats
- Space slats 1–1.5 in apart for breathability and a classic look.
- Secure each slat with two screws at each end, or use wood glue + clamps for a tighter joint.
Step 6 – Sand & Finish
| Grit | Purpose |
|---|---|
| 80 | Remove rough cuts & nail holes |
| 120 | Smooth the surface |
| 220 | Prepare for finish (creates a polished feel) |
- Sand the entire bench using an orbital sander or hand‑sand in the direction of the grain.
- Wipe down with a tack cloth to remove dust.
- Apply your chosen finish:
| Finish type | Appearance | Durability | Application tips |
|---|---|---|---|
| Oil (linseed, tung) | Warm, natural patina | Moderate (needs re‑oil annually) | Apply thin coats, let each soak for 15 min, wipe excess. |
| Exterior polyurethane | Clear, glossy | High (UV & water resistant) | Two–three coats, sand lightly (320 grit) between coats. |
| Exterior paint | Colorful, modern | High (if primed) | Use a rust‑inhibiting primer first. |
Step 7 – Final Touches
- Attach rubber pads to the bottom of the legs to protect flooring.
- Add throw pillows or a cushion for extra comfort.
5. Common Mistakes (and How to Avoid Them)
| Mistake | Why it hurts | Fix / Prevention |
|---|---|---|
| Using treated (MB) pallets for indoor benches | Off‑gassing chemicals can be hazardous. | Stick to HT or CP (commercially processed) pallets. |
| Skipping pilot holes | Screws split the board, weakening joints. | Always drill a pilot hole slightly smaller than the screw shank. |
| Over‑sanding against the grain | Produces splintery edges. | Sand with the grain, especially on hardwoods. |
| Applying thick coats of finish | Traps moisture, causing warping. | Thin, even coats; allow proper drying time. |
| Ignoring leg bracing | Bench may wobble under weight. | Install diagonal cross‑bracing or a center support beam. |
6. Cost Breakdown (Optional Detailed Table)
| Category | Item | Qty | Unit Cost | Total |
|---|---|---|---|---|
| Pallet wood | 48”×40” pallet (HT) | 2 | $0 (free) | $0 |
| Fasteners | 2½” deck screws (1‑lb box) | 1 | $5 | $5 |
| Tools | Circular saw (rented) | 1 day | $30 | $30 |
| Finishing | Outdoor polyurethane (1 qt) | 1 | $12 | $12 |
| Misc. | Sandpaper set (80/120/220) | 1 | $8 | $8 |
| Subtotal | — | — | — | $55 |
| Optional Extras | Wood glue, clamps, rubber pads | — | $15 | $15 |
| Grand Total | — | — | — | $70 |
If you already own the tools, your cost could drop below $30.
7. Frequently Asked Questions
Q1: Is pallet wood safe for a bench that will be used indoors?
A: Yes, as long as you use pallets stamped HT (heat‑treated) or CP (commercially processed). Avoid pallets marked MB (treated with methyl bromide), which are not recommended for indoor furniture.
Q2: How much weight can a pallet‑wood bench hold?
A: When built with solid joints and 2½‑inch deck screws, a 4‑ft bench can comfortably support 250–300 lb (≈ 115 kg). Adding a central support beam or diagonal braces boosts capacity further.
Q3: Do I need to treat the wood before finishing?
A: Lightly sand to remove splinters, then clean the dust. If you notice any knots or discoloration, a quick oil soak (e.g., boiled linseed oil) before the final finish helps the wood accept the coating evenly.
Q4: Can I use a nail gun instead of screws?
A: Screws are preferred because they hold better under shear stress and are easier to remove for future repairs. If you must use nails, add glue to reinforce the joint.
Q5: What if I don’t have a saw?
A: Many local hardware stores (e.g., Home Depot, Lowe’s) offer cutting services for a few dollars per board. Alternatively, ask a neighbor or a community makerspace to borrow a hand saw.
Q6: How often should I re‑apply the finish?
A: For oil‑based finishes, re‑oil once a year (or when the wood looks dry). Polyurethane can last 3–5 years outdoors; repaint or refinish if the surface starts to look chalky.
Q7: Can I paint the bench instead of staining?
A: Absolutely! Prime the wood with a rust‑inhibiting primer and then apply two coats of exterior paint. This gives a modern look while protecting the wood.
Q8: Is it okay to leave the bench outdoors year‑round?
A: Yes, if you use an exterior‑grade finish (polyurethane, spar varnish, or exterior paint). Consider adding a water‑proof canopy or covering the bench during harsh winter months to prolong its life.
8. Wrap‑Up: Your New Bench in Minutes
You now have everything you need to turn a couple of discarded pallets into a sturdy, stylish bench that can weather a summer garden party or add a rustic touch to your indoor hallway. The key takeaways:
- Choose the right pallets (HT, good condition).
- Take your time with preparation—remove nails, sand, and cut precisely.
- Build solid joints using screws and pilot holes.
- Finish with a protective coating tailored to indoor or outdoor use.
Ready to get started? Grab that free pallet, fire up your saw, and watch your simple design evolve into a piece of furniture you’ll be proud to showcase. Happy building!