What do you need?
- Plywood (Desktop size / for both top and bottom)
- 3×4 wooden stud (or any desired size / old molding can also be used)
- Dremel Multi-Max MM20
- Circular saw
- Circular saw guide
- Glue (any can be glue / wood glue is best)
- Miter box
- Nail gun
Divide the pallets into separate pieces. Use the Dremel Multi-Max tool to split the wood from the pallet (or use a hammer and stick) to cut the nails.
Remove all nails from the pallet board.
Using a circular saw, cut the plywood to the size you want your desktop to be.
We wanted the pallet boards to be narrower to work better with the chevron pattern, so we sized ours by 2.5 inches. To do this, use a table saw or circular saw equipped with a guide and cut the boards to the desired size.
Draw a line in the center of your plywood. This will serve as a guide for sorting the boards.
Lightly sand the pallet boards using the Dremel Multi-Max with the sanding attachment. If you don’t want your table to look rustic, you can sand more thoroughly.
We wanted the boards to be more contrasting in color, so we painted a few boards to make them darker.
Using the miter box, cut the ends of the pallet boards at a 45º angle.
Use three planks from the center (or inside) of the pallet to make the shelf under the table and cut to the size of your table using a circular saw.
Attach the three boards to the plywood table top using a drill and screws. Place one board at each end and one centered.
Arrange the palette boards in the pattern you want, using the line you drew as a guide. (Sheets will hang over the edge of your plywood)
Apply glue to the back of the pallet boards and lay them on the plywood. (The glue helps hold the boards in place while nailing, and you don’t need to use nails with lots of glue).
Hammer the pallet boards into the plywood using a nail and nail gun. (We used nails).
After all the pallet boards have been nailed, draw a line where the table edge is and use a circular saw to cut the pallet boards to size.
Make a frame for the table edge using the additional pallet board. Cut the wood by 1/8 ″ in addition to the thickness of your table.
Set the ends of the boards in a miter at a 45º angle.
Nail boards to the edges of the table to create a frame.
Using a circular saw, cut another piece of plywood to fit the planks under your table. I wanted the outer edges to be pallet wood, so we cut the two pallet boards to fit the edges and size the plywood to fit between them. You can only use a piece of plywood here if you wish.
Drill holes in the pallet boards (or plywood if you are just using them) where the legs will be attached.
Screw the board to the legs.
Once all four legs are attached to your pallet boards, place the plywood in between and screw it into place.
Place the bottom of the table on top of the table top upside down. Drill pilot holes at the bottom of the table.
Screw the two parts together.
Turn the table over and sand any rough spots.
If desired, cover the tray with polyurethane, follow the instructions on the box for usage and drying times.