Introduction: New Toolbox From Pallet Wood
It is not a difficult project so I don't have too many pictures during the process.
It is big enough to keep all my tools and other miscellaneous stuff out of my wife's sight. Win win!
Step 1: Pallet Dismantled
Using all the tool you have or you can imagine, dismantle the pallet carefully. Try not to injure yourself or the wood.
It is the most time consuming step and it requires a lot of strength (so using a crowbar might be a good idea).
Step 2: Start Building
After you are satisfied with the wood gathered, start building.
We started by building the frames for bottom and top of the box. Measure twice and cut, you need square angles.
Close the bottom frame using "bad" looking pieces of wood.
Step 3: Join the Frames
After you have the frames ready, start joining them using nice looking pallet pieces.
First attempt was as you can see in the pictures: no spaces left in between. But then my wife came and said: "this doesn't look like a pallet, this is a plain box, I don't like it". So we had to change the entire box and to leave some spaces between planks (hence no photos during this process).
Step 4: Make the Lid
We will use this toolbox as a table also, so we agreed we need some new wood pieces (the pallet didn't provide long and nice looking ones). We bought 5 pieces of wood, 2 meters long.
First one is fixed on top of the box, so we can attach the lid's hinges.
Lid was made using the other 4, we cut them at 1.2 meter and joined them using 2 small pieces.
Step 5: Attach the Lid
Using 3 gorgeous hinges, lid was attached to the fixed plank.
Step 6: Finishing
2 coats of teak colored lacquer applied. We will use it to renew the outdoor chairs, I hope the color will match.
Step 7: Fine Tunning
I didn't like that you can see the stuff we put inside the box, so I came with the idea to "close" the spaces using burlap. Burlap secured with staples, on the inside of the box and on the lid as well.