Anytime we make anything with pallets – whether it’s the canning cupboard or the buffet hutch – we will then use the left over 2 x 4’s that make up the pallet’s inside rails to build the carcass structure.
They are durable – and although heavy – they are free and make the structure strong. Speaking of the structure – we always use coarse drywall screws and heavy-duty construction adhesive to assemble.
The screws hold tight and the adhesive holds forever. Don’t worry about anything other than the framing being straight.
Once again if there are some left over bits of nail that have been sawed off smooth – let it be – it just makes for a great patina when stained or painted over.
Once we have the structures carcass built – we just simply use all of the straight boards cut from the pallets to cover. For this we will use the nail gun for speed and looks – but you could just as easily use a hammer and nails.
Once you have trimmed it out to your liking – you can paint, stain or leave natural – and you have a unique conversation piece.
The biggest piece of advice – don’t sweat the details! The biggest mistake people make when using reclaimed lumber or pallets is trying to make it too perfect.
It’s far better to not try to sand everything super smooth – or take out every little crack or dent in the wood. Let them be – it just makes it look that much better.
The real key is – whatever you build – make it yours and have fun with it!
Jim and Mary
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