Pallet Lumber Sorting Rack




Introduction: Pallet Lumber Sorting Rack

About: Don't believe everything you read online.

As I mentioned in a previous 'Ible, I have disassembled & recycled over 100 pallets this summer. I have numerous projects completed, but that's a LOT of lumber to use! Needless to say, it was stacking & piling up w no rhyme or reason. This weekend, I got the problem in hand.

Step 1: Design

A lot of the lumber racks I saw online were vertical on a wall, but I don't have a wall. My workbench is outside under some trees w an extension cord! I don't have 4x4s. What I have is pallets. LOTS of pallets! The basic design was to use pallets to support & sort the parts & pieces off the ground.

Step 2: A-Frame

The basic frame is simple & easy.
1) Take 2 pallets & attach in an A shape: touching @ the top & spread @ the bottom.
2) Secure w slat boards on either side w 2 nails each. Obviously, the boards need to be short at the top & longer @ the bottom. Using whole pallets & precut scraps, this was a good build for my 10-yr-old son.

If you only have 1 pallet to use, u can lean it up against a tree & strap w a ratchet strap. I used 7 pallets to build my "mini lumber yard" so I did both styles.

Step 3: Shelf Braces

I didn't have actual shelf brackets, but I did have rebar leftover from a concrete project.
1) Drill a hole w a hole bit big enough for the rebar to slide through. (I used 1/2".) Style & diameter of rebar varies. Punch completely through top slat just inside the 2x4 then angle down into the bottom slat as far as u can. U want a hole for the rebar to rest in at a slight up angle (~8*).
2) Space your holes wide enough & level enough to hold the boards. 2 holes per shelf is all you need. Space shelves ~18" apart vertically. On my short racks, I have 2 shelves on each side of the A-Frame. On the tall rack, I have 4 shelves on each side. I sort lumber by width, length, & thickness.
3) I cut rebar to 12" long & slid them in. Additional securement not needed. The rebar acts like a lever: hole in the back keeps it up while boards in front try to push it down.

Warning: Don't cut rebar too long! My first attempt was for 24" rebar shelves, but the weight that far out bent the rebar & spilled the boards. 12" is fine for the weight.

4) If there is no rear board to brace against, a single 10d framing nail can be used. Hammer it ~1/2 way into the 2x4 at the right angle to hold the rebar at the desired upward angle. Hammer it in angled downward to give it more resistance.

Be the First to Share


    • Made with Math Contest

      Made with Math Contest
    • Paint Challenge

      Paint Challenge
    • Laser Challenge

      Laser Challenge



    6 years ago on Introduction

    This is a great idea for keeping pallet slats organized and stacked nicely. Well done!