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

Michelle, Team member
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D.I.Y. outdoor pallet coffee table on wheels

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Project 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. Continue to step-by-step instructions
bent nail
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How to remove a bent nail

If a nail bends as you hammer it in, don’t try to straighten it, just remove it. The easiest way to do this is to place a thin piece of timber beside the nail to support the hammer and protect the surface. Fit the claw of the hammer under the nail head and pull the handle towards you until the nail comes out. Keep the handle as close to vertical as possible so you don’t make the nail hole wider.

Step by Step Instructions

1 Cut your timber
2 Remove the timber from the pallet
3 Remove the nails from the pallet slats
4 Make the first mitre cut for the frame
5 Measure and mark the length of the frame
6 Make the second mitre cut
7 Cut the timber for the inner frame
8 Measure and mark the inner frame
9 Cut the inner frame
10 Assemble the frame
11 Attach the inner supports
12 Measure and mark for the tabletop
13 Cut the timber for the tabletop to size
14 Secure the timber for the tabletop
15 Putty up the joints
16 Sand the table
17 Mark for the caster wheels
18 Attach the wheels
19 Apply the stain to the table
20 Enjoy your table
  • Step 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

  • Step 2. Remove the timber from the pallet

    Use the pry bar to lift the timber slats from the pallet.
  • Step 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.
  • Step 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.
  • Step 5. Measure and mark the length of the frame

    Measure and mark to make the second cut, ours was 850mm long.
  • Step 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.
  • Step 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.
  • Step 8. Measure and mark the inner frame

    Measure and mark the treated pine for the inner frame. Ours were 755mm long.
  • Step 9. Cut the inner frame

    Set the saw to 90 degrees. Cut the timber for the inner frame to size.
  • Step 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.
  • Step 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.
  • Step 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.
  • Step 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.
  • Step 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.
  • Step 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.
  • Step 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.
  • Step 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.
  • Step 18. Attach the wheels

    Pre-drill the holes for the wheels with the 3.5mm drill bit. Secure them with the 30mm screws.
  • Step 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.
  • Step 20. Enjoy your table

    Once your table is dry, you’re ready to enjoy your recycled, versatile outdoor coffee table.

Tools and Materials

Tools

  • Combination square
  • Cordless drill
  • 3.5mm drill bit
  • Earmuffs
  • Fixing gun and nails
  • Measuring tape or ruler
  • Mitre saw
  • Orbital sander
  • Paint brush
  • Pencil
  • Pry bar
  • Putty knife
  • Rags
  • Safety glasses
  • Work gloves

Materials

  • 45mm x 90mm F17 oak
  • 70mm x 35mm treated pine
  • 100mm cast iron swivel plate lockable casters x 4
  • 30mm hex head screws to attach the casters
  • Cabinet makers wax
  • Disposable gloves
  • PVA/wood glue
  • 240, 120 and 40 grit sandpaper
  • Stain exterior clear
  • Wooden pallet
  • Wood putty
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Health & Safety

Please make sure you use all equipment appropriately and safely when following the advice in these D.I.Y. videos. You need to be familiar with how to use equipment safely and follow the instructions that came with the equipment. If you are unsure, you may feel it is safest to consult an expert, such as the manufacturer or an expert Bunnings Team Member.

Grave health hazards are linked to asbestos, which may be in homes built up to 1990. Health hazards may result from exposure to lead-based paints in older materials and copper chromium arsenic (CCA) treated timber. 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. You can also use a simple test kit from Bunnings to indicate the presence of lead-based paint.
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