How to create the ultimate modern pallet bench from scratch!

At ToolMates, we’re always looking for new and creative ways to reuse the humble wooden pallet, from herb gardens to full outdoor lounge settings they are almost one of the most useful, re-purposed items going around.

Whether you’re a lover of re-purposing or you just need a bench in your backyard and don’t want to part with the cash, we’ve discovered the perfect solution that will put a smile on your face and allow you to put your hard earned cash towards something else in your home.

Here’s what you need to create ultimate modern pallet bench:


  • Hammer
  • Crowbar
  • Circular saw
  • Reciprocating saw
  • Table saw
  • Jointing jig
  • Safety goggles
  • Earmuffs
  • Cordless drill
  • Paintbrush


  • Wooden pallets – ideally from the same place
  • ½” OSB cut to your desired bench size
  • 2” x 4” of various lengths
  • Screws
  • Poly semi-gloss coating

Step 1
Get yourself prepared and organised before you kick off

Firstly you need to break down the wooden pallets before you get started. There are a number of ways that you can do this by either using a hammer or crowbar and pulling apart the pallets or you can use a circular saw to cut each of the stretches then using a crowbar to pull apart the joins. Or if you want to use tools you can use a reciprocating saw and a wood/metal blade to cut through the nails, which leaves the boards intact.

If you don’t have any of the above tools before you run out and purchase them, why not check out and borrow them from your local area? It’s super simple, and you can hire tools for a fraction of the cost.

Step 2
Prepare the boards

Next, now that you have your boards, you need to first remove the nails carefully using the hammer – and always wearing safety equipment. Don’t rush this process and be careful, as you don’t want to ruin your DIY experience by getting a nail in your hand or hurt yourself.

With the nails removed, it is important to get a straight edge, remembering this is going to be a bench for you to relax on. Using the jointing jig for the table saw, you can get a straight edge on all your wood & cut the other side with the table saw fence to ensure its parallel.

Step 3
All good things start from a solid base

Cutting the ½” OSB to the actual size you want your bench will provide an excellent platform from which to build your unit. So make your base and ensure it is really solid and sturdy for best results.

With this step done, start to glue & nail down the wood pallet into configurations that give you a nice pattern on the OSB. You can choose almost any pattern, by cutting your pallets down to different sizes and shapes to create the ultimate modern or ‘on trend’ look.

Step 4
Clean up the edges & add some strength to your new pallet bench


Once your glue is dry, tidy up the edges of the bench with your table saw. Using 2 x 4, add a frame to the sides and centre to give much needed added strength to your bench. Attach with screws and a cordless drill for best effect.

Step 5
Get decorative with your bench and add some paint

With some old farm wood I had lying around I got a little crafty and added in some decoration to my bench.

You can find this at most second-hand timber yards or a quick trip out of town to the regional areas, or simply use some nice timber you can find around your home or in your shed.  To add some decoration, you need to cut out the ‘side skirts’ of your bench and attach it to the sides, essentially wrapping the bench. Use liquid nails and 1½ inch screws to ensure that it is firmly in place and will stand the test of time.

When you use old wood sometimes, you can have large gaps appear. You can either choose to leave them or fill them. Using sawdust and wood glue, you can fill them and then lightly sand back to ensure the smooth edge. You don’t need to be too fussy about this as you are making a bench to be used outdoors; it’s really up to you.

Step 5
Add some legs for your outdoor pallet bench

Using more pallet lengths, create L-shaped legs, so they have a nice taper in them, offering a flush edge to your bench. After making the taper on each leg, cut the taper with your bandsaw.

Attach your legs with screws from the outside and liquid nails on the inside for stability. For extra stability, you could add some pocket holes into the 2 x 4 and even add a dowel piece as we did in our example with wood glue.

Step 6
Finish your pallet bench off

Add a couple of coats of gloss and give your bench a light sand to create something beautiful out of recycled and distressed timber. From time to time you can add some more paint or sand it back to add a rustic look; whatever suits the style of your outdoor area.

And there you have it – your very own pallet bench that cost nothing other than a bit of DIY, and a few bits and pieces you had laying around the house. Easy!

ToolMates offers a wide range of options for hiring and sharing your tools in your local neighbourhood. If you have plenty of tools lying around why not make some more by hiring them out to locals looking to undertake local DIY projects. Jump onto our website to find out more and sign up for your profile.

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