DIY Pallet Wood Pumpkins: A Rustic‑Chic Halloween (and Fall) Project
Transform reclaimed pallet wood into eye‑catching, farm‑fresh pumpkins that bring warmth to any autumn décor.
Why Pallet Wood Pumpkins?
- Eco‑friendly – Pallet wood is often discarded after a single shipment. Repurposing it keeps the material out of landfills and gives you a truly sustainable décor piece.
- Rustic charm – The weathered grain, nail holes, and occasional splinters add character that paint‑on pumpkins simply can’t mimic.
- Budget‑friendly – A single pallet (usually 4 × 8 ft) costs $10–$20, and you can carve dozens of pumpkins from one board.
- Customizable – Paint, stain, distress, or leave it raw—your pumpkin can match any style, from farmhouse chic to industrial loft.
Below is a step‑by‑step guide that walks you through gathering materials, cutting, shaping, finishing, and styling your pallet wood pumpkins.
What You’ll Need
| Category | Items | Tips |
|---|---|---|
| Wood | 1–2 standard 4 × 8 ft pallets (look for “HT” (heat‑treated) stamps; avoid chemically treated “MB” pallets). | Use the top deck boards—they’re the flattest and have the best grain. |
| Tools | – Circular saw or jigsaw – Power drill + #6‑8 wood drill bits – 1‑½‑in. spade bit (for pumpkin “stem” holes) – Sandpaper (80–120 grit) or a power sander – Clamps (optional) | If you don’t have a jigsaw, a handsaw and a coping saw work, but a jigsaw speeds up the curved cuts. |
| Safety Gear | Safety glasses, ear protection, dust mask, work gloves | Pallet wood can have splinters and dust—protect yourself! |
| Finishing | – Wood stain or paint (matte black, orange, natural wood, or white) – Clear matte polyurethane or wax – Optional: wood filler for nail holes, wood glue, decorative hardware (e.g., tiny hinges for “open” pumpkins) | Test stain on a scrap piece first; pallets can absorb dye unevenly. |
| Optional Extras | LED tealight, rope, burlap, twine, dried wheat stalks, faux vines, metallic spray paint | These give a polished, “ready‑to‑hang” look. |
Step‑by‑Step Construction
1️⃣ Prepare the Pallet
- Inspect & Clean: Lay the pallet flat. Remove any staples, nails, or loose boards with pliers or a nail puller.
- Sand Rough Spots: A quick pass with 80‑grit sandpaper smoothes splinters and preps the surface for stain.
Pro tip: If the pallet has a “knotty” or heavily stained side, turn it over. The cleaner side will take paint more evenly.
2️⃣ Sketch the Pumpkin Shape
- Print or draw a simple pumpkin silhouette (about 12–18 in. tall).
- Transfer the outline onto the pallet board using carbon paper, a ruler, and a pencil.
Why a silhouette? A flat‑cut pumpkin looks sleek and works well for wall‑mounts or tabletop displays. If you prefer a 3‑D pumpkin, skip the silhouette and cut a half‑ellipse (top and bottom) then glue them together.
3️⃣ Cut the Pumpkin
- Secure the board on a workbench with clamps (or a sturdy pair of sawhorses).
- Cut the outline using a jigsaw. Follow the line slowly; the wood grain will help guide the blade.
- Smooth the edges with 120‑grit sandpaper; a round‑file can help refine curves.
Safety note: Keep the blade perpendicular to avoid splintering the thin pallet wood.
4️⃣ Add the Stem & Details
- Drill a hole for the stem using the 1½‑in. spade bit near the top centre of the pumpkin.
- Cut a small “stem” plug from another pallet board (about 1 × 1 in. rectangular).
- Glue the stem into the hole with wood glue; let dry 30 min.
Optional: Carve a shallow “ripple” line around the pumpkin’s circumference for a natural, ribbed look.
5️⃣ Finish the Surface
- Apply wood filler to any nail holes or cracks. Sand smooth after it dries.
- Stain or paint:
- Rustic: Use a natural wood stain and wipe off excess for a weathered look.
- Bold: Spray paint orange or black, then add a contrasting white “glow” line along the rib.
- Seal: Brush on a thin coat of matte polyurethane (or wax) to protect the wood from moisture and dust.
Tip: For an extra‑glossy pumpkin (great for modern décor), finish with a satin polyurethane and a light coat of clear acrylic spray.
6️⃣ Hang or Display
- Wall‑Mount: Attach two D‑ring hooks to the back using 1‑in. wood screws; hang with a sturdy picture hook.
- Tabletop: Add felt pads to the bottom to prevent scratches.
- Outdoor: If you plan to place it outside, use exterior‑grade sealant and a stainless‑steel hanging rope.
Decorating Ideas
| Theme | Look | How to Achieve |
|---|---|---|
| Farmhouse Harvest | Natural wood + orange accents | Stain lightly, add a rusted metal hinge to the “open” side, place a small LED tealight inside for a warm glow. |
| Gothic Halloween | Black & white contrast | Paint the pumpkin matte black, outline the ribs in white chalk, insert a faux cobweb on the stem. |
| Minimalist Monochrome | White or charcoal | Spray paint the entire pumpkin white, add a single thin black line for the rib. |
| Vintage Scarecrow | Distressed wood + burlap | Lightly sand the edges, wrap burlap around the stem, spray paint a few faux “crows” with metallic silver. |
| Kids’ Craft Corner | Bright colors + felt | Paint in primary colors, attach velcro‑backed felt pumpkin “faces” that kids can swap out. |
Photo‑Ready Staging Tips
- Backdrop: Use a plain linen or burlap backdrop to keep focus on the pumpkin.
- Lighting: Soft, diffused natural light (near a window) eliminates harsh shadows. For evening shots, place a tealight inside the pumpkin and photograph with a low‑key background.
- Props: Pair with small pumpkins, gourds, or dried corn stalks for a layered composition.
- Angles: Shoot from slightly above to highlight the ribbed edges, then capture a side view to showcase the stem detail.
Where to Use Your Pallet Wood Pumpkin
- Front Door: Hang on a sturdy hook for a welcoming autumn entry.
- Mantel Piece: Group three or four pumpkins of varying sizes for a tiered display.
- Outdoor Porch: Secure with a weather‑proof rope for a spooky, lantern‑like glow.
- DIY Halloween Party Décor: Use as a centerpiece on buffet tables or as a backdrop for a photo booth.
- Kids’ Craft Room: Paint and personalize with each child’s name for a keepsake.
Frequently Asked Questions
| Question | Answer |
|---|---|
| Can I use pallet wood that’s been painted? | Yes, but sand it thoroughly first; paint can flake, causing uneven staining. |
| Do I need to treat the wood for outdoor use? | Absolutely. Use a exterior‑grade polyurethane or spar urethane to protect against moisture and UV. |
| What if I don’t have a jigsaw? | A hand‑saw combined with a coping saw works, but expect slower, less precise cuts. |
| How many pumpkins can I make from one pallet? | A typical pallet provides 8–12 usable boards. You can cut roughly 12–18 small (8‑in.) pumpkins or 4–6 larger (15‑in.) ones, depending on spacing. |
| Is pallet wood safe for indoor décor? | Yes, as long as you clean, sand, and seal it. Avoid pallets stamped “MB” (treated with methyl bromide). |
Wrap‑Up: Make It Your Own
Pallet wood pumpkins are more than just a craft—they’re a statement of sustainability, creativity, and seasonal charm. By following the steps above, you’ll have a rustic centerpiece that can be painted, stained, or left raw, fitting any décor style you love.
Ready to start? Grab that pallet from your local hardware store, fire up the jigsaw, and let those wooden pumpkins roll out of the workshop and onto your walls.
Share Your Creations!
We’d love to see how your pumpkins turned out. Tag us on Instagram @EcoCraftCorner with the hashtag #PalletPumpkin and get featured in our next roundup of DIY autumn décor.