When we received a back hatch for our car mailed with two pallets I knew I had to make something with them. They looked so cool with the aged appearance. I was thinking what I could make for this contest. We had just finished building a pond. It would be the perfect chair to put next to the pond. The chair is very comfy and it looks nice with the aged wood.
The supplies that you will need are
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Step 1: Disassemble the Pallet
Start by cutting three 2x4s five inches and one 7 inches. Place two of the 5 inch 2x4s under the pallet. Then place the 7 inch 2x4 atop the other two. Followed by placing the last 5 inch 2x4 on top of the plate. The final step is to get a hammer and hit the 2x4 on top of the pallet multiple times. Then continue this process until the pallet is full disassembled.
Step 2: Removing Nails Rom Pallet Wood
To start this process you first of all have to remove all the nails that our poking out of the board from when you took apart the pallet. Then, you will use a nail set and remove all the other nails.
Step 3: Cut the Wood
First we are going to cut the 2x10 into two 33" sections. Using the picture above you can sketch it out on the piece of wood and then cut.
To make the slats on the seat of the chair, cut the 1/2 x 5 pieces of wood from the pallet in half. Then cut them in into 21" sections. You will need 6 of them. While you're at it you can also cut the slats for the back of the chair. You will need 5 of them at 18 1/2" a piece.
The next piece of wood you need to cut is the front two legs. You will cut theses out of the 2x4s from the middle of the pallet. You will cut two of these at lengths of 26".
Next you will cut the front and back of the chair. For the front and back you will use the 1/2x3 1/2. You will cut these at 21". For the sides you will use the 2x4s on the inside of the pallet again and cut them at lengths of 20".
The next step is cutting the armrests. you will cut two at 21". On each of the sides you will cut out a square 1 1/2x1 1/2.
The last cut you have to make is for the piece of wood that covers the top of the chair. You will cut it out of the 1/2x5. it will be 18 1/2".
Step 4: Assemble the Frame
first of all, you will allign the front and back to make a square with the front and back on the outside. Then to make sure that it is perfect you can use a square. Next you will drive two nails into each of the corners.
After you have finished assembling the square you will add the legs. First you will start by tipping the square on its side with the front on the ground. Then you will place the first front leg in the corner. Then you will clamp it down and drill two holes and then fit the carriage bolts through them and fasten them on the other side. Once this process is finished you can move on to the other three legs.
Step 5: Securing the Seat and Back Support Boards to the Frame
Start by pre drilling holes in all of the boards. Then cut two pieces of wood at 13/16. These will act as spacers for you slats. You will start by cutting the first board to fit around the legs. Once you are finished you will place the two pieces of wood next to the first slat and bring the slat up and measure it to fit around the leg. Once you have finished cutting it you can screw the board down then you will repeat this process for the 4 other slats.
For the back supports you will do the same thing but start form the top and work your way down. You will also put one on the top of the chairs back. But this time you will use spacers that are 5/8". Once that is accomplished you will make you way down with the 4 left.
Step 6: Attaching the Armrests and Front Trims
You will first put them in place and they should rest level on the the back support board third from the top. Use pre-drill two holes on the one side where the square is in a diagonal pattern. Also, drill two on the front. Once this step is complete you can secure it to the chair using 4 two inch wood screws. Then you can do the same thing to the other arm rest.
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