Introduction: Reclaimed Wood Pallet Double Chair Bench
First off Hi, this is my first instructable.
I gathered ALL the boards here from Pallets i found. this entire project cost me less then $40
i used premium deck screws of 8×2-1/2" (as marked on their container) for all the 2×4 on 2×4 connections and 8×2" (as marked on their container) for all the boards to 2×4 connections.
and you will need several 2×4's without pallet lifter notches in them.
my extensive tool list is due to being nearly broke. i managed this with just a Skill Saw and a small cordless screwdriver.
Feel free to make use of many more tools if you have them. but i won't endorse going out to buy things you don't need. i would have loved a table saw though for this.
let us start with the Cuts of 2×4 be sure that if your wood is limited that you measure out all the cuts on the wood to ensure you have enough wood or to minimize the cutting you will have to do
2 - 2×4 58″ long Support
2 - 2×4 23 1/2″ long – Front Legs
2 - 2×4 22 9/16″ long Arm rest support
2 - 2×4 24 5/16″ long Rear Legs 15 degree angle on each end (cut ends parallel to each other)
4 - 2×4 at least 20 inches each depending on depth of your front board. see step 2
4 - 2×4 24″ long 15 degree angle on bottom only 15 degree angle up o backside Top is cut at a 90 degree angle and then rounded on the short end which is the back of the chair supports.
Step 1: Step 2 Master Your Wood
Now all pallet wood will be different. select a nice Wide piece for your front i slipped one of the 2×4 58″ behind it because i did not believe the piece itself was going to be strong alone.
here your long front board will need to be 61"
8 and 1/2 inch from the top of the Front legs only draw a strait line across. measure the depth of your long front board and the width and cut into your 2×4 legs below your line so that the board will fit into it flush. yes this is difficult with just a skill saw.
Here the 2×4 24 5/16″ long Rear Legs plus the front legs come together with the 2×4 22 9/16″ arm supports. Put 11" between the Top ends of the legs. be sure that back legs go out and back at the same 15 degree angle as their cuts they should be level with the arm rests and ground. My bench ended up with 4 arm supports rather then 2 because they ended up on the wrong sides. so be sure to put them on the inside of the bench.
the 2×4 58″ for the back goes between the rear legs at 8 inches off the ground and should be level with the ground and all the way forward at the botom edge
the 2×4 58″ that i stuck behind the front board should be level with the back 2×4 support
the Seat supports should go behind the front board to rest on the rear 2×4 cut 15 degree off the end so they are longer on top and fit the short end behind the front board on top of the front supporting 2×4 and on top of the rear supporting 2×4 flush on short edge.
the 2×4 24″ with the single 15 degree cuts go along the back side. Use a roll of tap or a rounded lid to round off the outside of the top end which is the short end after you have made the single 15 degree cut at the bottom edge. Place the Short end to the back so that the supports go away from the seats the first two go right up next to the inside of the armrest and first seat supports flush with the 15 degree cuts of the seat supports. from the inside of theses edges measure 16 inches and place seat supports. the last back supports then go to the inside closest to the center. don't worry this will get extra support later.
Step 2: Now the Easy Part
Support frame is now all done. you will want something to sit on and rest on.
20 1/2" inch long boards for the seats you will have to select the boards that take up this space the best or maybe put quarter inch gaps in if really needed. the front most board can overhang by 1/8th inch if needed or desired.
19" long should be the Back support boards. i used 3 of the same width board as my seats plus 1 thinner board at the top to go above the back support just slightly. here i used the smaller 2 inch screws to secure the boards into the supports. ( use as you see fit ) at least 1 screw at either end.
Step 3: Arm Rests and Table.
Measure the space between your chair back supports in the center and cut a 2×4 to fit. This will support the back of the table as well as reinforce the seat backs together.
using smaller boards to support the front put these behind the front board and next to the edge of your seats. as well as a 2×4 that is scrap to fit behind your support boards and is as or less then the width of the gap. This will also support the table. make this to a personal preference for height above the seats. make the back side just as high. Use the 2×4 you cut for the back space to set the height for the back.
Find some boards to fit between your seats for the table they will need to be 24 inches long, as well as the arm rest boards use the widest ones you have and you should use a large roll of tape or rounded lid on the outside corners. ( if you desire you may also do this to the inside edge of the arm rests. ) after you have best filled the spaces available you should be done with the entire structure. give it a good sanding if it is rough or needs cleaning as there can be various marks on pallet wood that are hard to remove.
once all this is done select a clear or semi-clear stain that will bring out your natural wood grains. i started with the bench upside down and supported it so that i could stain the underside and inside. Let dry flip upright and finish staining top. Let dry. sit,relax,enjoy a beverage.