1. I'm a tightwad and pallets are free.
2. It's an earth friendly way to repurpose something that would otherwise end up in a landfill.
3. I like making stuff.
4. It's a challenge.
So here is my chair. This is a very simple build based on other chairs I found online, and I adapted this to the lumber sizes I had. If you have a saw, a drill, and a pallet you can make this.I designed it so it is easy to modify to your own needs. You could easily fan the back, build it with curving back and seat, or make bigger or smaller based on your lumber, skill, and your taste.
Step 1: Pallets
I did it by driving a pry bar between the boards. Pry slowly so you don't break the boards. Once they're apart drive out all of the nails.
Step 2: Get Everything Together
I used 1 1/2" drywall screws to put everything together, and a circular saw and cordless screwdriver.
Step 3: Cut the Rails
After you make the cuts, sand everything. It's much easier now than once it all gets put together. You can see sanded and unsanded boards.
Notes: Don't trust the maker of the pallet to cut everything at a 90 degree angle. I try to cut the end off the board first... that way I know it is even, plus now it's smooth.
***THIS IS AN ALTERNATE CUT FOR THE BOARD***
So, if that one is hard to follow, or if you're just wanting to make it a little easier, use these rules instead. YOU DON'T NEED TO CUT BOTH! Cut 2 pieces of 1"x6" 33 3/4" long. Now go to one corner, measure over 2" and up 1/2". Make a mark and cut that little corner off (like what is in the top left of the picture). This won't give you the nice parallel legs once it's all done, but will still sit stable on the ground. It's not very noticable, however, since this cut is at the bottom rear of the chair.
Step 4: Make the Seat
Screw one to the front of the runners. Now measure back 19 1x2" and spread out the rest of the boards so they're evenly spaced and screw them in. Make sure that the pieces of the runner that you've cut the 2" corner off of is facing the ground. Sand everything.
You can easily use different size boards for the seat... just make sure you have at least 1/2" between the boards. This helps everything feel level and will let water run between the boards if it will stay outside.
Step 5: Make Back
Again, use whatever width board you have. This is flexible.
Step 6: Front Legs
Now measure up 15", and screw the top of the front of the chair to the leg.
If you couldn't measure the angles, just screw the board on. Then you can see how the corner sits on the ground, draw a line parallel to the ground and cut it off. Now cut the top off parallel to the ground.