Introduction: Pallet Sofa
So this is probably one of my favorite pallet projects. It is made of all reclaimed materials: pallets, cushions, pillows, and fabric is almost "reclaimed". The fabric is end of the spool remnants. Cushions were from old baby mattresses and pillows were reclaimed old pillow material. Super easy build. Check out below!
Step 1: Collect All of Your Pallets
First thing I did was collect a bunch of pallets. I ended up using 9 average size pallets. I chose to get the best quality ones I could find because I wanted this to last as long as possible. Also find some that have a cool brand wood burned or stamped in the front. It makes for a little extra detail.
Step 2: Cut All Pallets the Same Overall Width
I chose to cut all pallets at 27.5 inches wide so it was easiest to mix and match where I wanted my pallets. (back or bottom) after measuring, I cut straight across all of the slats, then removed the few inches still hanging onto the side 2x4. I reused the 2x4 by sliding it into the gap and reattaching it with nails. Overall length when laying out the length, I made a perfect L. 78" by 78".
Step 3: Create Your Cushions
I laid out my cushions on the pallet to see what length i would need overall. The first image here shows the left pallet upside down. I wanted to show how I extended the front 2x4 to hide the gap of the pallet being shorter than the cushions laid out. This spaces the pallet out a little bit when properly put together.
I found a bunch of baby mattresses when dumpster diving and thats what I used for cushions. This was the best find because that foam is expensive! I used the full width but for the rear I cut the mattresses in half and worked with that dimension. The material I used to cover the cushions and make all of the pillows was the only thing I paid for. It was $3 per lb. I bought it as fabric remnants from large rolls. I tried to use all reclaimed materials but this was the closest I could get for outdoor material.
*note: check out that chevron table top in the last photo*
Step 4: Securing the Backs
Secure the backs with a few screws. When you get to the corner overlap the pallets so you can screw in along the seam. I used 2 inch screws.
Step 5: Use It!
This is the best part. You're finished and enjoy it. Awesome for patio parties, bon fires, naps, etc. Do it all. I built it about 2 years ago and its still holding strong. I pressure washed it this year and its like new. I thought about staining it but I decided against it.