The Best Sandpaper for Pallet Wood – A Complete Guide for DIY‑ers
Whether you’re turning a discarded shipping pallet into a rustic coffee table or building a sturdy outdoor bench, the key to a flawless finish starts with the right sandpaper. Pallet wood is often rough, splintery, and treated with nails or chemicals, so choosing the proper grit, backing, and brand can save you hours of re‑work and protect your health.
In this post you’ll learn:
- How to read grit numbers and what they mean for pallet wood.
- Which sandpaper types (aluminum oxide, silicon carbide, etc.) work best.
- A side‑by‑side comparison of the top‑rated products on the market.
- Practical tips for sanding pallets safely and efficiently.
- Answers to the most common questions in our FAQ.
Ready to turn those battered pallets into polished projects? Let’s dive in.
1. Why Pallet Wood Needs Special Sanding
| Issue | How It Affects Sanding | What You Need |
|---|---|---|
| Rough surface & splinters | Large, uneven fibers resist fine abrasives. | Start with a coarse grit (60‑80) to level the surface. |
| Nail holes & dents | Gaps can clog sandpaper, reducing effectiveness. | Use a medium grit (100‑150) after the coarse pass to smooth out the holes. |
| Chemical treatments (heat‑treated, pesticide‑treated) | May cause dust irritation or degrade certain abrasives. | Wear a mask, choose a durable synthetic abrasive (aluminum oxide). |
| Variable wood density | Harder sections wear down sandpaper faster. | Keep a spare roll of sandpaper handy; consider a higher‑quality brand. |
Bottom line: Pallet wood is a “rough‑and‑ready” material that benefits from a staged sanding process—coarse → medium → fine—using a durable abrasive that can handle both soft sapwood and harder hardwood sections.
2. Understanding Grit Numbers
| Grit Range | Typical Use | Result on Pallet Wood |
|---|---|---|
| 40‑60 | Heavy material removal, shaping | Strips paint, removes splinters, flattens uneven boards. |
| 80‑100 | Primary smoothing after coarse | Eliminates deep scratches, begins to level the surface. |
| 120‑150 | Medium finish, preparation for finish | Smooths out remaining texture, ready for stain or paint. |
| 180‑220 | Fine finish, final prep | Produces a surface ready for clear coats, varnish, or polyurethane. |
| 320+ | Very fine polishing, between coats | Optional for ultra‑smooth surfaces on indoor furniture. |
Pro tip: For pallet wood you’ll rarely need anything finer than 220 grit unless you’re applying a high‑gloss finish. Going finer than 320 on a reclaimed pallet is often overkill and just wastes time and money.
3. Types of Abrasive Backings & Their Suitability
| Abrasive Material | Hardness | Best For | Not Ideal For |
|---|---|---|---|
| Aluminum Oxide | Medium‑hard, long‑lasting | General purpose, heat‑treated pallets | Extremely hard hardwoods (may glaze) |
| Silicon Carbide | Very hard, sharp | Fast removal on soft woods, finishing on metal/plastic | Heavy duty removal (blunts quickly) |
| Ceramic | Extremely hard, self‑sharpening | Industrial‑grade sanding, thick paint removal | Budget projects (expensive) |
| Garnet (natural) | Soft, produces fine finish | Hand‑finishing, delicate work | Rough pallet wood (clogs quickly) |
What to choose? For most DIY pallet projects, Aluminum Oxide is the sweet spot: it’s tough enough for the hard spots, inexpensive, and works well on both untreated and heat‑treated wood.
4. Top 5 Sandpaper Brands for Pallet Wood (2025)
Below is a curated table that ranks the best‑selling products based on durability, grit consistency, price per square foot, and user reviews from woodworking forums.
| # | Brand & Model | Abrasive Type | Grits Included (Pack) | Backing | Approx. Price* | Durability Rating (1‑5) | Best Use on Pallet Wood |
|---|---|---|---|---|---|---|---|
| 1 | 3M SandBlaster Pro | Aluminum Oxide | 60/80/120/150/180 | Cloth | $12.99 (5 ft²) | 5 | Full‑stage sanding (coarse → fine) |
| 2 | Mirka Gold Plus | Aluminum Oxide | 80/120/150/220 | Cloth | $14.49 (5 ft²) | 5 | Fast wear‑resistance, great for heat‑treated pallets |
| 3 | Norton GritGuard | Silicon Carbide | 100/150/220 | Paper | $9.75 (5 ft²) | 4 | Quick removal of splinters, good for soft softwoods |
| 4 | Sia Abrasives Super‑Sorb | Aluminum Oxide | 60/100/150/180 | Cloth | $11.20 (5 ft²) | 4 | Budget‑friendly, reliable for outdoor pallets |
| 5 | DEWALT DWS400 | Ceramic (dual‑coat) | 80/120/180 | Cloth | $19.99 (5 ft²) | 5 | Heavy‑duty projects, metal‑fastened pallets with stubborn paint |
* Prices are US retail (October 2025) and may vary by retailer.
Quick Pick‑Guide
| Situation | Recommended Grit Set | Brand |
|---|---|---|
| First‑time pallet project (budget) | 60‑120‑180 | Sia Abrasives Super‑Sorb |
| Heat‑treated pallets, need long life | 80‑150‑220 | Mirka Gold Plus |
| Heavy paint/chemical coating | 60‑100‑150 | 3M SandBlaster Pro (ceramic optional) |
| Outdoor bench, rough handling | 80‑120‑180 | DEWALT DWS400 (ceramic) |
5. How to Sand Pallet Wood – Step‑by‑Step Workflow
- Prep the Pallet
- Remove all nails, screws, and staples. A pair of pliers or a nail puller works best.
- Clean the surface with a stiff brush to dislodge dust and loose fibers.
- Safety First
- Wear a N95 (or higher) respirator, safety glasses, and hearing protection if using a power sander.
- Work in a well‑ventilated area; pallet dust can contain tiny wood particles and potential chemicals.
- Choose the Right Tool
- Hand sanding – Ideal for small pieces or intricate corners. Use a sanding block or a flexible pad.
- Random‑orbit sander – Fastest for large flat boards. Keep the sander moving to avoid gouging.
- Belt sander – Use only on very rough pallets; follow immediately with a finer grit orbital sander.
- Sand in Stages
| Stage | Grit | Action | Approx. Passes |
|---|---|---|---|
| 1 – Remove Roughness | 60‑80 | Flatten splinters, nail holes, and old finish. | 2‑3 (depending on board) |
| 2 – Level the Surface | 100‑120 | Smooth out deep scratches from Stage 1. | 1‑2 |
| 3 – Pre‑Finish Prep | 150‑180 | Eliminate minor scratches, get wood ready for stain/paint. | 1 |
| 4 – Final Smooth (optional) | 220 | For a glass‑like finish before clear coat. | 1 (light pass) |
- Dust Removal Between Grits
- Vacuum the board, then wipe with a tack cloth. Any remaining dust will embed into the next grit and cause unevenness.
- Inspection
- Run your hand over the surface. You should feel a uniform, slightly warm texture with no rough spots. If you still feel a snag, repeat the appropriate grit.
- Finish
- Once sanding is complete, apply your chosen finish (stain, paint, oil, or polyurethane). Follow the manufacturer’s drying times, then lightly sand with 220‑grit between coats for the smoothest result.
6. Maintenance Tips – Making Your Sandpaper Last Longer
| Tip | Why It Helps |
|---|---|
| Don’t press too hard with a power sander. | Excess pressure clogs the abrasive and wears it out prematurely. |
| Switch direction every few passes. | Prevents sanding lines and distributes wear evenly across the sheet. |
| Use a dust extraction port (if your sander has one). | Less dust means less abrasive loading and longer life. |
| Store sandpaper flat, away from humidity. | Moisture can cause the backing to swell and the grit to lift. |
| Trim the edges with scissors after the first use. | Removes the frayed edges that tend to catch and tear. |
7. FAQ – Your Most Pressing Sandpaper Questions Answered
Q1: Do I need a special sandpaper for heat‑treated pallets?
A: Heat‑treated pallets (marked “HT”) are not chemically treated, but the heat can harden the wood fibers. Aluminum oxide or ceramic‑coated sandpaper (like 3M SandBlaster Pro or DEWALT DWS400) works best because they stay sharp longer on the tougher surface.
Q2: Can I reuse the same sandpaper for multiple pallets?
A: Absolutely, as long as the grit isn’t clogged or worn down. After sanding a pallet, lightly tap the sheet to dislodge large debris, then vacuum or brush the surface before the next job. If the grit feels “soft” or leaves a glossy streak, it’s time to replace it.
Q3: Is paper‑backed sandpaper okay for pallet wood?
A: Paper backing is cheaper but tears easily when you hit tough spots (nail holes, knots). For most pallet projects, cloth‑backed sandpaper is worth the extra few dollars because it flexes with the wood and lasts longer under pressure.
Q4: What’s the difference between “abrasive grade” and “grit number”?
A: The grit number tells you the size of the abrasive particles (higher = finer). The grade (coarse, medium, fine, extra‑fine) is a marketing label that groups grit ranges. Always look at the actual grit number for precise selection.
Q5: Should I sand before or after I treat the pallet with a wood preservative?
A: Sand first to remove loose fibers and surface contaminants. After you apply a preservative or sealant, sanding again (with a fine grit) helps the next coat adhere better and eliminates any raised grain.
Q6: I hear about “wet sanding.” Is it useful for pallets?
A: Wet sanding (using water or a lubricant) reduces dust and can give a smoother surface, but it’s unnecessary for most pallet projects and can cause swelling in soft woods. Reserve wet sanding for final finishes on indoor furniture where an ultra‑smooth surface is required.
Q7: How do I avoid splintering when sanding the ends of a pallet board?
A: Clamp the board securely and start with a lower grit (60‑80) at a shallow angle, then gradually move to finer grits. Using a hand block gives you more control than a power sander at the ends.
Q8: My sandpaper keeps tearing—what’s wrong?
A: Most likely you’re using paper‑backed sandpaper on a rugged pallet or applying too much pressure. Switch to a cloth‑backed or ceramic‑coated sheet and let the tool do the work.
8. Bottom Line – Your Cheat Sheet for the Best Sandpaper
| Goal | Recommended Grit Set | Brand (Best Value) | Backing |
|---|---|---|---|
| All‑round pallet project | 60‑120‑180 | 3M SandBlaster Pro | Cloth |
| Budget‑friendly, occasional use | 80‑150‑220 | Sia Abrasives Super‑Sorb | Cloth |
| Heavy‑duty, paint removal | 60‑100‑150 | DEWALT DWS400 (ceramic) | Cloth |
| Fine indoor finish | 120‑180‑220 | Mirka Gold Plus | Cloth |
| Small, intricate pieces | 80‑150‑220 (hand block) | Norton GritGuard | Paper (if cost matters) |
Takeaway: Grab a cloth‑backed, aluminum‑oxide sandpaper set (60, 120, 180 grit) from a reputable brand like 3M or Mirka, and you’ll have everything you need for a smooth, professional finish on any pallet‑derived project.
Ready to sand?
Head to your local hardware store or favorite online retailer, pick up a pack from the table above, and start transforming those rough pallets into beautiful, functional pieces. With the right sandpaper and a systematic approach, you’ll spend less time sanding and more time enjoying the results.
Happy sanding!