Up-cycle With Pallet Wood and an Old Chair.

In this DIY, I turned a pallet and an old chair

into a New Rustic Style chair.

I used both the pallet palings and the pallet stringers in this build.

My sister was dumping a set of 4 upholstered chairs.

The chairs were full of mould and rot from flood damage.

I removed the foam and fabric and replaced it with pallet palings and

pallet stringers. There was nothing wrong

with the chair frame and just needed a coat of paint.

Supplies

The Supplies I used are quite minimal

and relatively inexpensive.

• One pallet (both the palings and stringers)
• Chipboard screws
• An old chair frame.
• Decking stain (in the colour Merbau)
• Black spray paint
• Brush on clear coat

Step 1: Before and After

Here is a bit of a look at the before and after.

My sister did not even recognize them

as being her old chairs.

Step 2: Old Chair

I first removed the old seat.

This was attached with 4 screws from the underside.

The backrest just slipped off over the top like a sock.

Step 3: New Seat

I cut some palings with extra overhang.

And laid them on the seat area.

I used the pre-existing holes in the frame to attach 2 of the 5 palings.

Step 4: Pallet Stringers

I cut the nails off of the pallet stringers, with an angle grinder.

I do this because it is easier and quicker than removing them.

I can then rip them in half length ways, down the table saw.

Step 5: Underside of Seat

I am attaching 2 lengths underneath the paling seat.

Pre-drill and countersink a hole, inline with every paling above it.

This is what will hold the entire seat together as 1 piece.

Step 6: Seat Overhang

Mark an overhang around the 2 sides and the front edge.

I used the width of my speed square as a guide.

Step 7:

I then removed the 4 screws from the underside of the frame.

Lifted off the seat and cut off the excess from around the edges.

Step 8: Sanding

I sanded the entire surface with an 80 grit

and then again with a 120 grit.

I also rounded over the corners a little with the sander.

Step 9: Backrest

The backrest was made in almost the same way as the seat.

I held up a few palings, cut with an extra long overhang.

Step 10:

I attached the top and bottom palings through the frame.

Then with 2 ripped lengths, I attached all 3 palings together.

Pre-drilled and countersunk a hole, inline with every paling.

This is what will hold the entire backrest together as 1 piece.

Step 11: Backrest Overhang

Mark out the overhang.

Remove the backrest and cut off the overhangs.

Sand and round over the corners

(in the same manner as the seat).

Step 12: Stain, Paint and Clear Coat

I used a water based decking stain in the colour Merbau.

Watered down to a 1:1 ratio.

For the metal frame, I used a black spray paint

to give the frame a fresh new look.

Once the stain had dried, I then gave the timber a clear coat.

Step 13: Final Thoughts

After doing this another 3 times.

We now have a full set of 4 recycled chairs.

For a pile of mouldy chairs on the footpath and a bit of

pallet wood. I think this reclaimed materials project turned out really nice.

Step 14: YouTube Video

I have a short, and to the point YouTube video

of this Up-cycled Chair project.

If you were interested in checking that out.