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D.I.Y. outdoor pallet coffee table on wheels

A completed outdoor pallet coffee table, complete with glassware, plate, oranges and a bottle of Pellegrino

Overview

We all love to recycle and this D.I.Y. project will show you how you can turn an old pallet into a rustic outdoor coffee table on wheels. It's easy to make, looks great and you can move it to wherever you want it.

Steps

1

Cut your timber

To make this D.I.Y. project even easier you can have your timber pre-cut at your local Bunnings*. Here's the cutting list we used for this project:

45mm x 90mm F17 Tasmanian oak for the outer frame:

  • 850mm x 2
  • 550mm x 2

70mm x 35mm treated pine for the inner frame:

  • 755mm x 2

*Not available at all Bunnings stores.

The tools and materials necessary for making an outdoor pallet coffee table on wheels

2

Remove the timber from the pallet

Use the pry bar to lift the timber slats from the pallet.
Planks being removed from an old pallet with a pry bar

3

Remove the nails from the pallet slats

Use the hammer to straighten up the nails as much as you can. Then bang the nails back through the pallet slats. Use the claw of the hammer to pull out the nails. Repeat this until all of the nails have been removed.
Nails being driven out of a length of wood salvaged from a pallet

4

Make the first mitre cut for the frame

Set the mitre saw to 45-degrees. Make the first cut close to the end of the timber.
A piece of timber being cut at 45 degrees for a corner piece

5

Measure and mark the length of the frame

Measure and mark to make the second cut, ours was 850mm long.
A tape measure and pencil being used to mark a length of wood

6

Make the second mitre cut

Set the saw to the opposite 45-degree angle from the first cut. Cut the timber to length. Repeat the previous steps to cut the other 850mm length for the frame and the two 550mm sides for the frame.
A 45 degree mark being ruled onto a length of timber for a corner piece

7

Cut the timber for the inner frame

Set the mitre saw to 90 degrees. Take both pieces of timber for the inner frame and cut them near the ends to 90 degrees.
Two lengths of timber being cut to size

8

Measure and mark the inner frame

Measure and mark the treated pine for the inner frame. Ours were 755mm long.
Two wooden lengths being measured and marked for cutting to size

9

Cut the inner frame

Set the saw to 90 degrees. Cut the timber for the inner frame to size.
Two lengths of timber being cut to size

10

Assemble the frame

Apply glue to the ends of the timber for the external frame. Join them together, making sure the ends are flush. Use the fixing gun to secure them. Wipe away any excess glue.
A corner joint being secured with glue

11

Attach the inner supports

Apply glue to one of the long thicker sides of the internal supports. Place them so they're flush with the bottom of the outer frame. Use the fixing gun to secure them.
Glue being applied to a length of wood in a zig zag pattern

12

Measure and mark for the tabletop

Measure the distance between the outer frame, ours was 460mm. Transfer these measurements to the timber from the pallet.
A tape measure being used to measure the distance inside a wooden frame

13

Cut the timber for the tabletop to size

Set the saw to 90 degrees. Cut all of the timber for the tabletop to size.
A length of timber being cut to size

14

Secure the timber for the tabletop

Place the timber for the tabletop into the frame. Make sure it's evenly spaced. Use the fixing gun to secure it.
Planks being laid into a wooden frame

15

Putty up the joints

Putty up the mitre joins. You can choose to leave the nail holes exposed for a rustic look, or putty them for a more finished look. Let the putty dry.
Putty being used to seal the joints in a pallet coffee table

16

Sand the table

Once the putty is dry, start sanding. Start with the rougher 40 grit sandpaper and graduate to 120 then 240 as necessary. Depending on your taste, you can leave the pallet with a rustic look, or sand it back so the tabletop is flush with the outer frame.
The surface of a pallet coffee table being sanded down

17

Mark for the caster wheels

Turn the tabletop over. Place a caster wheel in a corner so that it's flush. Mark for where the screws will go. Repeat this for the three other wheels.
The underside of a pallet coffee table being marked with a pencil to position castor wheels

18

Attach the wheels

Pre-drill the holes for the wheels with the 3.5mm drill bit. Secure them with the 30mm screws.
A castor wheel being secured to the underside of a pallet coffee table

19

Apply the stain to the table

Use a paint brush to apply the Cabot's exterior clear. When you do this, make sure you're working in a well ventilated area.
The surface of a pallet coffee table being varnished

20

Enjoy your table

Once your table is dry, you're ready to enjoy your recycled, versatile outdoor coffee table.
A completed outdoor pallet coffee table, complete with glassware, plate, oranges and a bottle of Pellegrino
Health & Safety

Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.

When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.