Tools: hammer, prybar or mallet, sawsall, orbital sander, pneumatic nail gun, table saw, table router, Photoshop, large plotter
Materials: old pallet, 3/16” foam core, hardware
Step 1: Disassembly
Step 2: Tips and Tricks
Number one: How do you get under a sheared nail head without gouging the wood?
Flip the lumber over and use another nail to tap the broken bit out!
Number two: How do you pull a long nail with no head?
Don't waste your time with pliers, just bend the nail over to the side! Now you have some surface area to pull out normally.
I mainly wanted the slats and didn't plan on including the 2x4's in this project, so didn't worry about buried nails. However, I might change my mind later, so I made sure to mark any remaining nails to avoid surprises.