Last fall I made this Wooden Coffin for a Halloween decoration, all from pallet wood.
In this instructable I will try to show you how I made it, for the ones that like Videos, instead of pictures. I have included the video I made while making this. When I made this, I didn't have no plans, except what I wanted in my head. I have tried to document as much as possible so that you could follow along. If you get lost in the Instructions, check out the video, it might make more sense.
This is a easy pallet project, the only parts I had to buy was staples. This can be made in a few hours, and it doen't have to be perfect, you want that old aged look.
Step 1: What You Will Need
You will need the following:
Pallet wood ( you will need at least 2 pallets or more)
Circular Saw, Jigsaw, or a Bandsaw
Air Stapler or hammer
Pencil , pen or marker
Staples, Nails or screws
Note only use pallets that have a HT stamped on them, these pallets are Heat treated, with no chemicals.
Step 2: Step 1
First we will build the Bottom of the Cofffin, you will need at least 3 wider slats, around 5 3/4" wide to follow my dimensions or use enough smaller slats for the same width.
Measure at the top 10" wide, as shown in the pictures, then 12" down. At the bottom, measure 15" wide just like the pictures, use a long straight edge to connect the lines. Then use a Circular saw or Jigsaw to cut the pieces.
When cut it should look like the last picture.
Step 3: Step 2
Now for the sides, find yourself 4 boards, as close to the same size as possible, if not rip them down.
Measure the long side of the bottom piece and cut them to that length, this will vary from the lenght of your pallet wood. Then cut a couple of short pieces to attach to them with staples. I didn't use any glue here, but you could use some, if so I would use Titebond II glue made for outdoor projects.
Note I choose to use 2 boards for my sides, you could use 3 and make the Coffin a little thicker.
Step 4: Step 3
This is what your long side pieces should look like, now lay these to the side and we will work on the other pieces.
Step 5: Step 4
Now cut some short pieces to match the length of the sides closer to the top. Also attach these with staples or nails like we did the longer rails.
Step 6: Step 5
Now we need to cut some braces to attach the sides. I used some of the 2x4 from the pallets. Cut the pieces down to fit in between as shown in the pictures. These sizes will vary from your widths.
Step 7: Step 6
Flip you bottom piece over and staple them like shown. If you don't have a stapler, use nails or screws.
Note I left some of the nails in the pallet boards for character, so watch when sawing or nailing.
Step 8: Step 7
Rip some more pieces from the 2x4 parts of the pallet for the side braces. Attach those to the sides as shown in the pictures.
Note if you have a helper, you might not need the clamps as shown. My Son wasn't around then, but my Cat was, but i couldn't get her to help. LOL
Step 9: Step 8
Cut 2 boards to fit the top portion of your coffin, make them the same way we made the side rails.
Note I am leaving the bottom portion of the Coffin open, if you want to close it off. Cut some pieces to fit it.
Step 10: Step 9
Now we are going to work on the Door, I didn't have any more wide boards, so I had to use several narrow ones.
I laid out my boards on my table, and then laid the bottom part on top of it, marked the outline with a marker. Then attached some other scrap pallet slats to it. Then took it to the Bandsaw and cut the outline.
If you don't have a Bandsaw, you can use a Circular Saw or Jigsaw. You might want to cut the rails with marks before attaching braces.
Step 11: Step 10
Now attach the door the the Coffin, I made mine just for decoration, not to fuction, so I stapled my door to the Coffin.
If you want the lid to open, you will have to attach some hinges.
Step 12: Step 11
I ripped a couple of pallet scraps to make some stakes that I could put into the ground. I cut these at a point on the end. Then stapled these to the back side of the Coffin.
Step 13: Enjoy
Now find you a good spot to put it, I have a old Saw that my Grandfather used to cut wood in my front yard.
I stuck it into the ground at a slight angle, then put some fresh dirt in front of it like it came up out of the ground. I then made this wood skelton to put beside of it. I will try and make another Intructable on it. Thanks for checking out my Instructable, I really enjoy making stuff, and glad to share to Instructables.
I hope this encourages somebody to make this, if you make one, please upload a picture, I would love to check it out. Thanks for taking the time of reading my Instructable.
P.S. I forgot, I put some Vinegar and Steelwool mixed together over the whole piece, to get a more aged look. Plus my Son painted the R.I.P.