PART III - CONSTRUCTION - This is continuation of the complete start to finish tutorial on how to create a beautiful rustic pallet cabinet from scratch, using free wood pallets. Follow along as we'll research, sketch, gather/dismantle pallets, cut, build, stain and finally install our one of a kind pallet cabinet.
Watch Part I - Research and Development
Watch Part II - Gather and Dismantle Pallets
Watch Part III - Construction
Thank YOU!! to Mrs. Jackie Hoegger and the entire team at Hoegger Communications for all the help and constant support. Thank you, Hoegger Comm rocks!
REQUIRED TOOLS AND MATERIALS:
Above are the tools I used to construct our rustic pallet cabinet. A.) Dismantled Wood Pallets (see previous sections of this tutorial for details on how to do that.) B.) Saftey Glasses C.) Circular Saw D.) Drill (w/phillips head driver and E.) Clamps F.) Tape Measure G.) Hammer H.) I.) 1'' Multi-Material Construction Screws J.) 6D 2'' Bright Finishing Nails K.) Rubber Mallet L.) Carpenter's Pencil
-- NOTE - Hardware will be installed in the next section
Important note - Make sure you have your sketched out dimensions! (See previous sections of this tutorial for more information.) This sketch will be our road map that will guide us safely along as we build our pallet cabinet.
Important note - Always dry fit your boards! Lay your boards on top of or next to each prior to any cutting or nailing/screwing. This helps to visualize exactly how the pieces will look together. Dry fitting is important with recycled wood because no two pieces are the same, each piece has its own unique character. You'll want to dry fit to make sure everything works and looks well together. It may take some rearranging before you get it looking just how you'd like. Always dry fit.
Initial Framing - Built out of 2"x4"s from our wood pallets. We cut the - 'A' - to be the height of our cabinet and -'B' - to be the depth, then secured together with 6D 2'' Finishing Nails.
Important! This frame is not our final finished dimensions! If you plan to install your cabinet into a tight space, like we are, calculations are crucial! We will add slats on the top of the frame, that will increase our height by aprox. 3/4'' of an inch. Also we will add slats to the back, each side and front, so that will increase all of those dimensions by 3/4'' of an inch. And if you plan to add feet to the bottom of your cabinet, which we are not, keep in mind the height of the feet and make sure to calculate for that.
Our son Kingston helping Daddy with some measurements.
Building Walls.- Now that we have our two frame - 'A' - we are ready to attach the walls - 'B'. First, dry fit the pallet slats. Here it's important to dry fit because some pallet slats will have unwanted knots, bends or gaps. It's like a puzzle, and you might need to do rearranging until you find the best lay of slats for your walls - 'B'. Don't be overly selective, and don't be a perfectionist though. We want that rustic look that comes from imperfections!
Once you've dry fit all your slats - 'B' into place and you know the order in which you want to lay your slats, we hammered 6D 2'' Finishing Nails to secure the walls - 'B' - to the frame 'A'. Notice, we haven't cut the slats yet.
Trim the excess slats with a circular saw. We used wood clamps and clamped a slat to the walls and used that as a guide for the saw to ensure a clean straight cut.
Dry fitting the back wall. It's important to dry fit because no two pallet pieces are the same, they all have their own unique character. You'll want to dry fit them to make sure they work, look and sit well together. It may take a few switching around of the slats to get it looking just how you'd like it.
IMPORTANT NOTE - The length of these slats will be our cabinet width. Check the measurements, cut and nail together with 6D finishing nails.
Attaching back wall.
Adding face. A = pallet slats. B = our cabient. Nail the slats into the 2x4's in our frame.
Ledge to hold shelf. We used 1'' x 2'' wood purchased from Home Depot rather than the 2'' x 4''s from the pallets to help reduce the weight of the cabinet.
Measure and cut down slats and lay them on top of the 1'' x 2'' ledges. The shelves are not fastened down.
Do the same thing at the bottom. We could have simply placed the slats on the 2'' x 4''s but we installed the 1'' x 2''s to give us an extra 2'' depth to the cabinet.
Adding Roof - Nail slats - A - into the 2'' x 4'' frame - B - to create the roof. The Back Splash - C - is simply the rear wall -D- extended up above the roof.
Build Doors - The doors are made entirely out of slats secured together with 1'' multi-material constructions screws. After measuring the width of our cabinet opening, we knew we had enough space for 5 slats, we split that between the 2 doors. One slat was a bit too wide and had to shave 1'' inch off the length.
Wiping down after sanding. Removing any remaining sawdust.
Construction complete. Sanded and wiped down. We're ready for stain, hardware and installation into the house! We're almost done!
6D FINISHING NAILS - $3.47 | 1lb Box
WOOD FOR LEDGE - 1'' x 2'' x 8 foot strips - $4.37 x 2 = $11.00
1'' SCREWS FOR DOORS - $3.00
SANDPAPER - Had in garage.
TOTAL COST SO FAR: $17.47