How to build a pallet wood chair – Part 2

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How to build a pallet wood chair – Part 2

Welcome to Part 2 on how to build a pallet chair! This post will share every detail on how to build this easy and comfy wood chair from scratch.

To view the finishing details of this chair…

Visit Part 1 HERE


So let’s build!

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How to build a pallet chair – Part 2


pallet wood patio chair build via Funky Junk Interiors

Materials I used:


2 pallets of equal size – any size will do, but the key is that they are the same.

4 square posts for legs

2 cedar planks for arms

Long screws

Cordless drill

Miter saw

pallet wood patio chair build via Funky Junk Interiors



1. Start with two pallets of nearly equal size if you can. One will be your seat and the other will be your back.

2. Sand the pallets well, especially where you’ll come in contact to the chair when sitting. I started with coarse sandpaper, then moved to finer grit using a palm sander.

Caution: Since pallet or reclaimed wood can be contaminated, please do wear breathing, hand and eye protection while building.

3. Cut the 4 support leg posts to desired size, then sand until smooth.

The height of the legs will be determined upon the kind of padding you choose for your chair.

The arm length (front to back) should slightly extend beyond your pallet seat depth.

– – – – –

My chair measurements are:


padding – new 5″ foam

legs – 25″ high

arms – 5.5″ wide x 32″ long

pallet seat – 42″wide (left to right) x 30″ deep (front to back).

pallet backer – 42″ wide (left to right) x 36″ high.




pallet wood chair build via Funky Junk Interiors

4. Dry fit all the chair components to make sure they fit well.

I also placed something underneath the bottom pallet to determine the height I wanted for the seat before attaching.

I chose to not attach the backer pallet because I had a railing for support. Allowing it to lean also offers you a nice comfortable angle to lean against.

If you wish to attach the back, I’d rig up a support board behind the back that attaches to both arms.

pallet wood patio chair build via Funky Junk Interiors

Create seat supports:


5. Cut 2×4 chunks to fit, then attach into place with screws. 

Before the seat pallet was attached to the foot posts, it was reinforced with small cuts of 2x4s.

The small reinforcements give the legs something more to grab onto.

6. Determine the height of your seat.

To determine the height of the seat, you’ll first need to decide what you’ll be upholstering the seat with as part of the height.

I placed boxes underneath the pallet to help determine the desired height.

The height of my seat from floor to top of pallet is 12″.

pallet wood patio chair build via Funky Junk Interiors

pallet wood patio chair build via Funky Junk Interiors

7. Attach seat to the legs by pre-drilling holes, then attach with screws.

Turning the seat pallet on its side, the legs were attached with for screws as shown above.

Pre-drilling the holes will really help for assembly.

pallet wood patio chair build via Funky Junk Interiors

Adding chair arms


8. Screw on your choice of board armrests.

I chose cedar planks that were wide enough to hold a cup of coffee.

And signing them up is a fun twist too!

View Farmers’ Market stencil from HERE

I used this Farmers’ Market stencil to create the sign.

pallet wood patio chair build via Funky Junk Interiors

pallet wood chair build via Funky Junk Interiors

Pretty funky, right?!

pallet wood patio chair build via Funky Junk Interiors

Adding upholstery


9. Choose your seat cushion.

Pallet wood is obviously not comfy so you’ll need to figure out some kind of padding. I purchased brand new foam for the seat that I had it cut to size at an RV foam place.

I chose 5″ foam because I did a trial on a sofa cushion we had and I loved how it felt! 5″ foam is not cheap though, this seat alone ran me $100ish. But if you can land some reclaimed foam, you’ll save a bundle.

I do suggest to sit on the foam you choose to ensure it’s comfy as the density chosen will determine the softness.

Outdoor foam is another option, but it can double the price. I just bring this foam piece indoors when it’s damp outside.


pallet wood patio chair build via Funky Junk Interiors

Pallet wood outdoor sofa via Funky Junk Interiors

(click for larger photo)

Pallet sofa reveal from 2012

Pallet sofa build from 2012

I also built this pallet wood sofa using reclaimed foam. It is 6″ thick and super soft.

Below is a little tour of getting the foam custom cut new…

cutting foam for upholstery-001

Getting new foam cut


Getting new foam cut for your pallet wood chair is not the cheapest option, but it is a good one if you have an odd-sized pallet you can’t outfit anything else with.

cutting foam for upholstery-001

cutting foam for upholstery-001

Kingdom Mattress Factory foam shop

I got this foam cut at Kingdom Mattress Factory in Chilliwack, B.C.

Fred used a foam cutter, and glued chunks together creating the exact size cushion required. It could have been cut out of one chunk if he had it on hand. You can’t feel the seams at all so it worked out great!

Update: The joins later separated, so if you can get 1 solid piece, I’d recommend that.

Also shown above is a glimpse of the green reclaimed foam I purchased intact and custom built a pallet sofa around.

Visit the larger pallet sofa in THIS POST.

Pallet wood outdoor chair via Funky Junk Interiors

The bean sack covers


I chose to use coffee bean sacks because they are pre sewn and I love the look!

Pallet wood outdoor chair via Funky Junk Interiors



The large 26″ pillows were slipped into the bean sacks, then the edge flapped over towards the back. The pillows fit perfectly!

The seat


The bean sacks are loosely wrapped around the seat foam. I just didn’t want to sew, but you certainly could.

They are a little itchy when you sit on them with shorts, but during those times, I just plunk a blanket down first and all is well.



Because the foam is not outdoor durable, all the foam, pillows and sacks come in at night or during damp weather so they don’t get mouldy. It’s a little bit of back and forth, but I find the comfort of the chair outweighs the work involved.

I have a special place underneath the sofa where I slip the foam into hiding when it’s not being used. Underneath a bed is where the larger one resides.

I hope I’ve inspired you to try your hand at this easy pallet wood patio chair build! You can do this one!

Besides… you can rest in complete comfort after your efforts… and all summer long too! Think you’ll give one a go?

Pallet wood chair reveal – Part 1 *HERE*


rusty gear blog branding with junk

Other pallet furniture to make:


Pallet sofa reveal from 2012

Pallet sofa build from 2012

How to know if pallet wood is safe.

My other pallet wood creations.

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Categories: All Cool Projects, Burlap, DIY, Furniture, How To Build, Reclaimed wood projects, Tools & Building
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82 thoughts on “How to build a pallet wood chair – Part 2

  1. It’s awesome! The sign arm rest takes it to another level. And don’t sell your skills short, do you realize there are those of us who have A+ builders in our family who show them YOUR projects and say “make it exactly like that”?


  2. HI. Thanks for the tips on the foam! Do you put any sealer on your outdoor wood pieces? I’m building a table and have lots of choices on how to finish it. Decisions.


    • Hey Casey, no sealer whatsoever! My patio is covered from the elements so I’ve never bothered. I’ve found most pallet wood to withstand weather pretty well unprotected though but it isn’t a bad idea!

  3. Wow, I am in LOVE with this chair! Thanks for the inspiration and I think I may just have to attempt this project this weekend because I have 2 pallets outside that have been waiting to be transformed 🙂


  4. Thanks for sharing Donna, I love your tutorials and great looking furniture! My huband and I just got a hold of 100 + pallets I can’t wait to see what he makes out of these!

  5. I’ll be celebrating Cinco de Mayo with some super nachos, a pitcher of margaritas and making this!! Really cool!! And perfect timing actually 🙂

  6. I love the pallet sofa and chair! Please build versions for indoors! I have been contemplating this very thing and have been paralyzed with fear! I can’t wait to see what you whip up!!

  7. I saw this today and have already found two pallets and intend to start making this weekend, wish me luck, I think your idea is fantastic.

  8. Oh my goodness! Super cute sofa. And so funny, I bought a framed coffee sack of that “Cafes do Brazil” that you have as a pillow from a local gas station! Now I have something good to do with those pallets hanging out in the barn…

  9. Hi Donna.

    Love this post. I’m so sad though, in New Zealand you can’t really reuse pallet wood, trust me I’ve tried. It’s awful rough sawn pine with lots of splinters. I made planter boxes out of some once but they were awful to work with and didn’t look that great. A shame.

    Keep up the great work!

    • Hi Donna.. Try sanding with coarse sand paper first then use fine sandpaper. It really makes a difference in working with the wood..

    • Hi Leah. Have a look around some different places for pallets. Most are in poor state but occasionally some good ones come along. It can depend on the industry/use… And you have to work the sander/elbow pretty hard but they can come up nice. Good luck. Matt (NZ)

    • Hey Leah, I use a palm sander.. it’s mandatory! You could also go a step beyond with a belt sander. I’ve been debating on picking one up myself. Ours can be very splintery as well so sanding is totally needed.

  10. I have an old futon frame, I was thinking about using to make some sort of chair, or loveseat. What are your thoughts on that?

  11. Hi,
    These are adorable! I’m wondering if the wood is treated or if I need to treat it to leave them out in our back yard?

    • Hey Michelle! I did not treat the wood as it’s under cover. I’ve never found that pallet wood deteriorates all that quickly anyway. But to be safe, yes, it would be a good idea to treat anything wood that will get hit with all the weather elements.

  12. What a beautiful love seat! Did London drugs just give you the pallets?? I’ve never seen them there before. I’ve always wanted to build things with pallets but never know where to find them. On that note, where did you get the coffee bean bags, too??

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