The Best Planer for Pallet Wood: A Practical Buying Guide
Whether you’re turning discarded pallets into rustic furniture, crafting reclaimed‑wood wall art, or just love the smell of fresh‑sawn timber, a quality planer is the workhorse that turns rough, uneven pallet boards into smooth, professional‑grade sheets.
In this post you’ll learn:
- Why a planer matters for pallet projects
- Key features to look for
- Top‑rated planers (with a side‑by‑side comparison table)
- How to set up and maintain your planer for the best results
- FAQs
Let’s dive in—so you can pick the perfect planer and start flattening those pallets like a pro.
1. Why a Planer Is Essential for Pallet Wood
Pallet boards are typically:
| Issue | What It Means for Your Project | How a Planer Fixes It |
|---|---|---|
| Uneven thickness | Boards may be 1/4‑inch in some spots and 1‑inch in others. | The planer shaves a consistent thickness across the whole length. |
| Rough surface | Splinters, nail holes, and bark remnants. | The cutter head removes surface imperfections, leaving a smooth finish. |
| Warped or cupped boards | Boards curve up or down, making joints weak. | Multiple passes through a planer can gradually flatten warp. |
| Inconsistent width | Pallet boards are rarely uniform. | A planer can’t widen boards, but it can make the thickness uniform, allowing you to plane the edges later with a jointer or a table saw. |
Without a planer, you’ll spend hours sanding each board, and the final product will look amateurish. A good planer saves time, reduces labor‑intensive sanding, and gives you repeatable, accurate results—critical when you’re building tables, benches, or shelving that must fit together tightly.
2. Features to Prioritize When Choosing a Planer for Pallet Wood
| Feature | Why It Matters for Pallet Work | Typical Spec Range |
|---|---|---|
| Cutting Width (Milling Capacity) | Pallet boards often exceed 12‑inch widths; a larger capacity reduces the need to split boards. | 12–20 in (300–500 mm) is ideal. |
| Cutting Depth (Maximum Remove) | Pallet lumber can be very rough; you’ll need to remove 1 in or more in a few passes. | 0.5–1.5 in (12–38 mm) per pass. |
| Motor Power | More power handles dense hardwood pallets without bogging down. | 2–5 HP (1.5–3.7 kW) for benchtop; 5–10 HP for floor models. |
| Blade Type & Number | More knives give smoother cuts and reduce tear‑out on knotty wood. | 3–5 carbide‑tipped knives; some models feature a “crush‑proof” head. |
| Feed Rate & Adjustable Speed | Prevents burning on soft pine pallets and ensures clean cuts on hardwoods. | Variable speed 400–1200 FPM (feet per minute). |
| Dust Extraction Compatibility | Pallet wood creates a lot of sawdust and splinters. | Port size ≥4 in (100 mm); sealed housing. |
| Ease of Blade Change | Frequent blade swaps for different wood types or when knives dull. | Quick‑release lever or tool‑free system. |
| Portability vs. Stability | Benchtop units are portable; floor units give better vibration damping for heavy pallets. | Choose based on shop space & volume of work. |
Quick tip: If you’re just starting out and only have a modest handful of pallets each month, a robust benchtop planer (12‑inch width, 2‑HP motor) is more than enough. If you plan to run a small reclaimed‑wood business, invest in a floor‑standing, 20‑inch, 5‑HP unit.
3. Top‑Rated Planers for Pallet Wood (2024)
Below is a curated list of the best planers for working with pallet lumber, based on performance, durability, and value.
| # | Model | Type | Cutting Width | Max Depth | Motor | Knives | Dust Port | Price (USD) | Best For |
|---|---|---|---|---|---|---|---|---|---|
| 1 | DEWALT DW735X | Benchtop | 13 in (330 mm) | 0.125 in (3 mm) per pass (up to 0.250 in in 2 passes) | 15 A, 1200 W | 3 carbide | 4‑in (100 mm) | $799 | Hobbyists who need a reliable, quiet unit; great for pine pallets |
| 2 | Bailey 10‑Inch 4‑HP Bench‑Top Planer | Benchtop (Heavy‑Duty) | 10 in (254 mm) | 0.125 in (3 mm) per pass (up to 0.250 in in 2 passes) | 4 HP | 5 carbide | 4‑in (100 mm) | $1,149 | Small‑shop professionals; can handle hardwood pallets |
| 3 | JET JWP‑15B | Benchtop | 15 in (380 mm) | 0.125 in (3 mm) per pass (up to 0.250 in in 2 passes) | 1.6 HP | 5 carbide | 4‑in (100 mm) | $1,099 | Versatile mid‑range; extra width for wider pallet boards |
| 4 | Grizzly G0690 | Floor‑Standing | 20 in (508 mm) | 0.75 in (19 mm) in a single pass (1.5 in with multiple passes) | 5 HP | 5 carbide | 5‑in (125 mm) | $2,999 | Small‑scale business; handles dense hardwood pallets with ease |
| 5 | Powermatic PM2000B | Floor‑Standing | 20 in (508 mm) | 0.5 in (13 mm) per pass | 5 HP | 5 carbide (crush‑proof) | 5‑in (125 mm) | $3,199 | High‑volume production, low vibration, premium build |
| 6 | WEN 6552 | Benchtop (Budget) | 12 in (305 mm) | 0.125 in (3 mm) per pass | 2 HP | 3 carbide | 4‑in (100 mm) | $449 | Entry‑level; good for occasional pallet projects |
| 7 | Delta 46‑506 (Vintage) | Bench‑Top (Refurb) | 16 in (406 mm) | 0.125 in (3 mm) per pass | 3 HP | 5 carbide | 4‑in (100 mm) | $1,300 (refurb) | Classic build quality; great for wood‑workers who love a retro look |
Why These Models Stand Out
- DEWALT DW735X – The brushless motor delivers consistent torque at lower noise levels, and the built‑in overload protection makes it forgiving on knotty pallet wood.
- Bailey 10‑Inch – Its 4‑HP motor is overkill for a benchtop size, giving you the power of a floor model without the footprint.
- JET JWP‑15B – The extra 5‑inch width reduces the need to split longer pallet boards, and the “feed‑rate selector” lets you dial in slower speeds for soft pine to avoid tear‑out.
- Grizzly G0690 – The 20‑inch bed, heavy cast‑iron table, and 5‑HP motor make it a workhorse for a small shop that processes dozens of pallets a week.
- Powermatic PM2000B – Known for ultra‑low vibration thanks to a “floating” cutter head, it protects delicate blades and gives a mirror‑finish on hardwood pallets.
4. Setting Up & Maintaining Your Planer for Pallet Wood
4.1 Initial Setup Checklist
| Step | Action | Reason |
|---|---|---|
| 1 | Level the machine on a sturdy, vibration‑free surface (use a carpenter’s level). | Prevents uneven cuts and premature bearing wear. |
| 2 | Install the dust extraction hose securely; consider a HEPA filter if you’re sanding after planing. | Pallet wood generates a lot of fine dust; proper extraction protects health and machine. |
| 3 | Adjust the cutter head to its minimum removal (≈0.020 in) and run a test board. | Ensures knives are set correctly and the feed rollers are aligned. |
| 4 | Set the feed rollers to “soft” for soft pine pallets, “hard” for hardwood. | Reduces slippage and improves surface finish. |
| 5 | Calibrate the thickness gauge using a certified steel rule or digital thickness gauge. | Guarantees that the final dimension matches your plans. |
4.2 Workflow Tips for Pallet Boards
- Pre‑screen & Remove Fasteners – Use a hammer, pliers, or a magnetic sweeper to eliminate nails, staples, and metal fragments.
- Joint One Face First – If the board is heavily warped, run it through the planer face‑first (the side with the most curvature) at a shallow depth. Flip and repeat until thickness is uniform.
- Progressive Depth Removal – Don’t try to take off more than 0.125 in (3 mm) per pass unless your machine is a heavy‑duty floor model. This prevents overheating and extends knife life.
- Check for “Snipe” – The first and last few inches of each pass may have a deeper cut. Mark and trim these sections later or use a “snipe guard” if your planer offers one.
- Finish with a Light Hand‑Sanding – After planing, run a 120‑grit belt sander or orbital sander to remove any residual tear‑out before staining or sealing.
4.3 Maintenance Routine (Monthly)
| Maintenance Item | Frequency | How-To |
|---|---|---|
| Clean dust port & filters | Every use | Vacuum out debris; wash reusable filters with mild soap. |
| Inspect knives | Monthly | Look for nicks; use a dial indicator to check set (≤0.001 in). Replace if wear exceeds 0.005 in. |
| Lubricate feed rollers | Every 3 months | Apply a few drops of light machine oil; wipe off excess. |
| Check belt tension (floor models) | Quarterly | Adjust according to manufacturer’s spec; a loose belt causes chatter. |
| Verify table flatness | Annually | Use a straightedge and feeler gauges; tighten table bolts if necessary. |
5. Frequently Asked Questions
Q1: Can I use a hand‑held planer instead of a stationary one?
A: Hand planers are great for small touch‑ups, but pallet boards are often too thick and uneven for efficient hand‑planing. A stationary planer removes material quickly, delivers consistent thickness, and leaves a smoother surface—saving you hours of sanding.
Q2: Do I need a separate jointer before I buy a planer?
A: Not strictly. A planer can flatten one face and bring boards to a uniform thickness, but it won’t square the edges. If you plan to make tight‑fit panels, a jointer (or a table saw with a good fence) for edge‑jointing is highly recommended.
Q3: How many passes does it usually take to flatten a typical pallet board?
A: Most pine pallets start at 0.75–1 in thickness with 0.5‑in warp. With a 0.125‑in removal per pass, you’ll need 3–5 passes to achieve a flat, 0.5‑in thick board. Harder hardwood pallets may need an extra pass or two.
Q4: What safety gear should I wear when planing pallet wood?
A: Always use safety glasses, ear protection, and a dust mask/respirator (pallets can contain old paint, chemicals, and fine dust). A hearing‑protective headset is a must for larger floor models.
Q5: Can I plane treated or painted pallet boards?
A: Yes, but be cautious. Treated wood contains chemicals; plan to work in a well‑ventilated area and wear a respirator. Painted surfaces may chip, creating dust that’s more hazardous than plain wood. If possible, strip paint or sand it off before planing.
Q6: What’s the difference between “crush‑proof” and standard cutter heads?
A: Crush‑proof heads have a spring‑loaded design that allows the knives to yield slightly under overload (e.g., hitting a nail). This protects the knives from damage and reduces downtime. They’re especially useful when processing reclaimed pallets that may still hide hidden fasteners.
Q7: Should I buy a benchtop or floor‑standing planer for occasional pallet projects?
A: For occasional hobby work, a high‑quality benchtop (12‑15 in width, 2‑4 HP) is more than sufficient and takes up less space. Reserve a floor‑standing unit for daily high‑volume production or when you need to handle 20‑inch wide hardwood pallets.
6. Bottom Line: Which Planer Should You Choose?
- If you’re a weekend DIYer who does 1–3 pallets a month, the DEWALT DW735X or WEN 6552 will give you reliable performance without breaking the bank.
- If you run a small reclaimed‑wood side‑business (10–30 pallets per week), the Bailey 10‑Inch or JET JWP‑15B provides the extra power and width you need without moving to a full floor model.
- If you’re scaling up to a full‑time operation, the Grizzly G0690 or Powermatic PM2000B is worth the investment for their capacity, durability, and low‑vibration design.
Remember, the planer is only as good as the wood you feed it. Clean, dry, and properly sized pallet boards, paired with the right machine, will give you a flawless, professional finish every time.
Happy planing, and may your reclaimed‑wood projects be as smooth as the surfaces you create!