How to Build Wood Pallets

Written by pamela gardapee
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How to Build Wood Pallets

Wood pallets can be used in manufacturing warehouses or for everyday use around the home. Using pallets in leaky basements will protect items from water damage. Knowing how to build wood pallets yourself will save you money. For businesses, building pallets internally reduces the cost of running a business.

Skill level:
Moderately Easy

Things you need

  • Three Pieces of Wood, 3 1/2 inches wide by 1 1/2-inch thick by 48 inches long
  • 10 Pieces of Wood, 3 1/2 inches wide by 3/4 inch thick by inches long
  • 54 threaded wood nails, 2 1/2 inches long
  • Hammer
  • Saw

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  1. 1

    Use the saw to cut three 48-inch-long pieces of the 3 1/2-inch wide by 1 1/2-inch-thick wood (these are called stringers). Cut 10 pieces at 40 inches long out of the 3 1/2-inch wide by 3/4-inch thick wood (these are called deck boards).

  2. 2

    Use a saw to cut out two 6-inch wide by 1 1/2-inch high slots on the three 48-inch wood stringers. This step is only necessary if you are making a four-way pallet to be used with a pallet jack. The pallet jack has a 33-inch wide spread with each fork six inches wide. Measure in 7 1/2 inches from each end of each of the three stringers to find your first cut. Next, measure from your first cut mark over six inches and make a mark for your ending cut. Measure from the bottom of the stringer up 1 1/2 inches and mark for your height cut. See photo for how the three pieces will look after the cuts.

    How to Build Wood Pallets
  3. 3

    Nail the deck board to the very end of the stringer using two 2 1/2-inch nails. Place the other end stringer under the deck board and attach with two 2 1/2-inch nails. Place the middle stringer in the centre between the two end stringers and attach with the two nails. Then attach the deck board to the other end of the stringers with two nails on the end. Attach the middle deckboard in the centre of the pallet. Caution: If you're making a four-way pallet, make sure that your slots on the ground and not facing upward to the deck of the pallet.

  4. 4

    Flip the pallet over and add a deckboard to each end and the centre as you did in Step 3. This will be the bottom of the pallet.

  5. 5

    Flip the pallet over to the deck side with the pallet jack slots facing downwards. Add two deck boards on each side of the middle board, spaced evenly.

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