My girlfriend Wanda just moved from an apartment with a dry balcony, because the upper neighbors balcony was her roof, to an apartement with a balcony without a roof. So things get wet and blown away by the wind. She likes some cosy stuff on he balcony like flowerpots and pillows. With sunny weather no problem off course but we've got some pretty rainy and windy days here in Holland so she wanted a waterproof box to keep things tidy and weatherproof and even better if it would double for a bench......well...: It happens she has her birthday the 4th of april (yes,that's today) and I just like to make stuff out off pallet wood....So let's fix that box.
Step 1: Materials and Tools
Apart from the pallets I used the following tools and materials:
To dismantle the pallets
- steel brush
For making the box:
- saw (I usually use my Japanes one but a normal one will do as well)
- a drill/screwdriver
- a rule
- a tacker and staples
- a pencil
- some imitation leather
- silicon caulk
- caulking gun
- a brush
Step 2: Prepare Pallet
I could tell a lot about how to dismantle a pallet but I think there are enough, and probably much better instructables, about that so take a look at for instance this one.
I used a few for this one, I can't really tell you how much pallets exactly because they come in a lot of different sizes and I had a lot more that I will use for other projects.
Enough for now is to say that you'll have to remove all nails and try to take them apart as careful as you can otherwise you will only end up with fuel for a barbecue.
Step 3: Meassure and Cut
For this box I used the following lengths:
- 77 cm 10x - long sides
- 38 cm 10x - short sides
- 50 cm 8x - corners
- 88 cm 5x - the top
- 33,5 cm 2x- the top
- 38 cm in half in the length - the handles
I used a piece of flake-panel 35 cm by 77 cm for the bottom and one of 30 cm by 70 cm for the seat. This can be made of other plywood or underlayment as well off course.
Step 4: Construct and Screw
Ok, now some serious construction work.
I started with the corners and then screwed the short sides on these. When made both the short sides fit in the long sides and after that screw two slats on the insides at the bottom of the box. On these slats the bottom plate will fit.
Step 5: Bottom and Top
Now the rest of the wood will be used for the top-lid.
Just five planks hold together by screws and the two 34,5 cm planks. If placed good these will fit on the inside of the box.
Now make the bottom out of plywood of your choice (or even make it out of more pallet wood) and fit it on the slates at the bottom of the box.
The box will be ready if it will fit and hold two kids in it....
Step 6: The Seat
I had some rest foam lying around and glued two pieces together with Bisontix. Than glued the foam on the flake-wood and than after cut it in size, tacked the purple imitation leather around the foam. Just try to go from one side and than tack it on the opposite side and so round.
The seat I screwed on the lit. But first did some finishing
Step 7: Make Watertight
I used silicon caulk to seal all the holes and cracks. A bit of a dirty job if you are not careful. Try some water with soap on your finger to spread the silicon out.At
Step 8: Finishing
At the end I screwed the handles on and did some finish with laquer, but off course you could use any stain, paint or other sealer to protect the wood. Remember this was a pallet and depending on the state or treatment of the wood in it's former live it will need more or less protection against the weather.
I hope this will be some inspiration for you, I enjoyed making it and even enjoyed it more when I gave it to my girlfriend who is very happy with her box.