Hi, I’m Craig Phillips in this video I’m going
to show you how to build your own chair using recycled pallet wood. And the tools you’re
going require a chop saw or a handsaw drills, screws, tape measure, clamp set square and
an orbital sander. Now once you’ve decided the size of your
chair you can start to build one section of the frame. So I’m going to place that to
one side and start to cut myself clips apart starting off with the longest length is 900.
I’m going to cut this square to start with and then kind of create a triangle end on
them to finish the top section off. We can adjust the chop saw to cut them at
45-degree angles if you haven’t got a chopped short of course you can achieve that on your
normal handsaw as well. Turn that over same again, okay so one sides a little bit higher
than the other because as we come up later on with the laterals one of them meet and
the other one sits on top of them like this. The next stage is we want to come across
480 millimeters so we’ll take one of these. I’m going to cross it over onto the back leg
at the moment I’m going to measure across there at 480. It this piece is going to do
here and of course we want it 480 for the height which is this section here so now by placing them three pieces of wood
we can start to see the shape that we’ve go. We’ve got the back, the seated area and then
the height of what the seat sits at because this is only one piece of timber. This is
not going to be strong enough to make a frame up like this we want to double it up and sandwich
these together so the next stage is you want to cut a piece of timber from here to here
and also another one from here to here and from there to there.
Okay so that now is a double layer of the frame that we want to achieve on there all
we have to do now is glue it and screw it all together. The position let’s place back
down on top lining up the peaks, squaring them back up again screws in that side these
are all about 40 millimeter screws because the timber itself is about 20, 22 millimeters
thick it’s going right through the first piece ripping into the one below again just double-checking,
you keeping it squared at all times before you drive the screws in.
Okay so that is one more side of it complete now if my measurements serve correctly we
should marry up on top of them nice and square. Perfect, so now all we’ve got is the two side
sections of the chair built up. All we need to do now is cut more pallet slats to bridge
across between them to make the seat. Now the width of your chair is for you to
decide on but I’ve chosen to go 440 millimeters I’ve caught a selection of timbers that are
going to be fixed across one side of the frame to do the other. Now working on your own
can be a little bit tricky so what I’ve done is screw a couple of blocks into the workbench
here and then screw the bottom of the frame in there and that just holds them upright
for me. As always we put plenty of glue on any sort
of furniture that’s taking anybody’s weight then we start to fix our slat across the first
one I’m going to apply flush to the very edge of it here a couple of pallet holes stop the
wood from splitting and again I’m driving 50 millimeter nails
in nice and deep. Before I put that second one in I’m going to do the one the opposite
side here and just make sure I’m getting it nice and square.
Yeah I’m happy with that that’s nice and square. Perfect, the next lot I’m just going
to place down for now before actually screw it in because I want to create a little small
gap in between each of the seat slats and of course if you’ve screwed them down you’ve
committed to them then so we’v e jus placed them, yep that’s working quite well.
A couple of millimeters yeah once you’re happy with that and then you can start to fix all
of them down. Now I’ve just put one screw in each timber in there for the moment I’m
going to put two on it I’m going to do the opposite side now before I continue fixing
that side down again just double-checking that you’ve got the same size gaps between
them and then you can get a fixing in the opposite side.
Okay so that’s the base the seated area of the chair now complete what I’m going to
work on now is cutting more slats the same size and working it up across back.
So this is the back slat now it should be fixed on the back here. Now again we want
to create small little gaps in between them but what I have done is cut little chocks
then I’m going to slide underneath because I’m working upwards you’ve got a tendency
of slipping down. These are about 10 millimeters so I’m putting
4 along here 10 millimeters in between each one of them just about take me up to the top
but before I do I’m going to drill all the clearance holes with a pallet drill bit.
Again plenty of glue, making sure again it’s flushed to both sides and if you’re happy
with that you start to screw him down. We’ll put two in these but I’m just going to continue
getting the rest in place to double-check that they all fit before we put the second
screw in each side. Looking well and then you can commit with
your second screw and then okay so that’s more or less the back complete except I’ve
got to fear that slat again 440 millimeters and remember earlier on we cut these on a
bit of a peak so I’m going to place my chalk back underneath that top one. I’m going to
glue and screw that one into position and then also I further one on the back it all
helps the destruction and the strength of the chair but it just finishes off that little
peak for us and then when we sand this down later we can take off any harsh edges there
as well with the sander. Drill some pallet holes, plenty glue although
to make it a bit easier because it’s a bit tall there now and I’m not the tallest of
people. So I’m going to start my screws off halfway through the wood this way it makes
it a little bit easier. Here we go always double checking flush both sides. And then
we can commit a screw there to hold it and then the one on the back of course you
don’t need to put any packs in there a little bit of glue so that’s now the back and the
seat all fixed into position. The next stage is to reinforce the bottom
of the legs now bracing the legs is very important because if there’s any weight on here what
you don’t want is the legs to force out all to force in there>So of course you can just
fix battens to the front of them, screws them in and that would be strong but aesthetically
it doesn’t look that good. So what I’m going to do is maintain my joints
45 degrees so when they go together there’s a nice snog and strong joint and we do this
by taking our measurements across, getting our set square drawn on it 45 degrees there
90 off that way and turn over finding bottom of that mark and then again 90 on there.
Now, I’m going to chop these on the chops or of course if you don’t have a chop saw
you can put them in your workbench then with your handsaw.
Okay so that’s now our corners all cut and mitred at -90° they will fit in between there
quite well. So we start off by fixing this one down I want to place it in the middle
of these two back legs there. I’m going to mark it then I’m going to drill some pallet
holes and place this into position with the screws.
Now I’m going to put that probably about 70 or 80 millimeters off the bottom of the
leg itself, okay so that’s one in. Now I’ll take my tape measure I can measure it from
the bottom it’s coming up about 150 millimeters and I’ll do the same again from the bottom
back of this leg. Now this next piece is now going to be fixed into that mitred area right
in there. So again what we want to do is get plenty of glue behind and drill a couple of
pallet hole to be able to do a fixing from there into this timber. Turn on the side that
way we drill a little bit of an angle into here.
Sometimes drilling them you have to start off upright and then just turn the drill as
you go down on an angle. Plenty of glue on that joint. There it is nice and tight, okay.
Put the screws in here they’re going to shoot in on that angle that we drilled and catch
that timber that’s already fixed in place. You do exactly the same around all the rest
of the three legs. Now the four main braces are in holding all four legs together for
extra precaution I’m just going to place another one right in the very center here.
Place that more or less ithe very center if you unsure double-check with your measurements;
180, 180 perfect. When it’s in position you can drill some
pallet holes from the outside and drive your screw in to hold it into position. Now that
is real solid now. The last thing just to finish thing just
finish the entire chair off is a piece right across the front. Now that’s the entire structure
of your chair built, all you need to do now is sand it down.
Unscrew that and lift it away from the jig. And that’s how you make your chair out of
recycle pallet wood and I’ve got to say they’re extremely comfortable. If you want to see
some more video tips on pallet projects please visit the website, silverlinetools.com