Step 1: Materials
Really it depends on the size of the gaps in your pallets and what you can get your hands on but you will want some lengths of wood suitable for filling in those gaps when we get to "Finish cladding exterior"
You'll also need a good supply of timber screws at least 45mm long
Depending on how fussy you are, you may wish to purchase some dressed/finished timber for your top trim/ledge....otherwise you may be able to use some of the pallet offcuts.
I did the former (1200mm x 180mm x 12mm)
Step 2: More Materials
In addition to these, you will need a pool pump. I have used a Bestway 1/4 hp unit with sand filter because I need adequate head pressure for the solar heating I will be installing on my roof at a later date :)
Something smaller would be ok if you aren't heating yours :)
Step 3: Recommended Tools
Hacksaw or cordless reciprocating saw.
Cordless drill/driver with phillips bit and a small drill bit for pilot drilling timber as well as holesaw attachments to suit whichever size jets you are using.
A heat gun is optional but highly recommended.
Step 4: Fitting Jets and Initial Pipework
Once the jets are in you can begin plumbing up your PVC pipework....being sure to use the appropriate PVC cement.
Step 5: Constructing the Frame and Fixing Down Edges of the Liner
Use your drill driver the screw the pallets together. Back side of of one pallet overlaps perfectly onto the end of another.
The gaps should be sufficient enough for the nosecone of your drill to get through
Once this is done you can cut the top off your IBC (if you hadn't already) and cut vertically down each of the corners down to the level of the top of the frame.
Using the heat gun, heat up the plastic, allowing it to be folded over and screwed down onto the frame.
If you look at the finished product, you will see why this gives a much more professional look.....
Step 6: Connecting Your Pump
I recommend the flexible hose connections just because they give you a little bit of breathing room if you need to repostion or replace the pump.
I have fitted isolation valves so that if the pump needs to be replaced at any point, those can be shut off and no water need be lost from the tub.
If you do in fact wish to change the water, the IBC has a dispensing valve at its lowest point.....which is just perfect (shown)
I recommend leaving a cut-out in your pallet/ frame for easy access to this :)
Step 7: Capping It Off
Avoid too much inner overhang if you don't want to encroach on the already small area.
Pallets aren't generally engineered to exacting standards so you may find yourself packing certain parts up with thin slivers of wood to get the capping nice and level.
I fixed mine down with 12G stainless hex drive screws. Not only because they look pimp, but also because its the one area where the screws are likely to get splashed with water.....and rust is U.G.L.Y
Step 8: Finish Cladding Exterior
The wood I am using was "whatever I could get my hands on" and so it turned out to be thicker than the slats of the pallet. I quite like the effect. I think it adds some dimension.
Step 9: Fill and Enjoy!
You will need to decide what water treatment strategy you are going to take. Personally I am using chlorine tablets in a floater (not shown) because its the easiest by far with really no fuss.
The challenge I set myself here was to keep cost down without compromising the quality of the end product.
I am in the fortunate position of being able to get my hands on a lot of these materials for free.
The pump was my only cash outlay at $100 for a good second hand unit.
If you had to fork out for every single part, then this is probably a $500 project (assuming you already have tools)
This is my first ever instructable so I hope I have done an alright job.
Thanks for reading!