Nothing beats a workbench, except having a workbench you made from scratch. This green workbench seems to kill two metaphoric birds with one stone. It reuses wooden cargo pallets and creates a new work surface. This gem of a project is relatively straightforward and easy as most of the construction has already been completed for you. With the addition of four legs and some bracing, you are well on your way to enjoying a new workbench.
Disassemble the pallets, using a pry bar to separate the strut blocks from the planks.
Using a nail puller, remove all the embedded nails in the planks and support struts.
Familiarize yourself with the schematics detailing the various measurements for the table. Note the measurements are in millimeters. One millimeter equals 0.0393700787 inches.
Measure eight planks and mark them at 36 1/2 inches. Use a hand saw or Sawzall to cut them to size. These will be the legs.
Using a support strut (or block) as a 90 degree angle pivot, screw two leg planks together at a time. Use the 1/4-inch wood screws and hand drill.
Measure four planks and mark them at 18 1/2 inches. Use a hand saw or Sawzall to cut them to size. Two of these planks will be used to brace the legs and the other two will be used for the short sides of the table.
Measure two planks and mark them at 47 inches. Use a hand saw or Sawzall to cut them to size. These will be used for the long side of the table.
Measure nine planks and mark them at 21 inches. Use a hand saw or Sawzall to cut them to size. These will all be used for the workbench surface or tabletop.
Screw two 18 1/2-inch planks to the two 47-inch planks. This is the basic frame of the tabletop.
Place the nine planks vertically on the frame. (See the photo in Step 3).
Screw the planks to the frame, placing one screw at either end.
Turn the tabletop over and place each 90-degree angle leg joint into a respective corner. Using wood screws and a hand drill, screw the legs to the frame.
Screw two planks (cut during Step 6) between two corresponding legs, bracing the workbench and providing greater stability.
Never use nails on pallet wood as they will splinter the wood.
Be careful when using either a hand saw or Sawzall. Always wear eye protection.