Recycled pallet outdoor bar

A great addition to any outdoor entertaining space that will have you sipping drinks in style.

How to build an outside bar

You will need

Materials

1 – 2 pallets, depending on their size (we used a 2200mm – long heavyduty pallet)
7 pallet slats, removed from a second pallet (enough for a shelf, shelf supports and corner covers)
2 x 75mm 100kg load capacity wheels (optional)
2 x 75mm 100kg load capacity wheels, with brake (optional)
16 M8 x 50mm coach screws (optional; for wheels)
35mm external timber screws
100mm external timber screws
Macrocarpa slab the size of your base, plus 100mm overhang on each side (ours was 1600mm long and approx. 500mm wide)
Resene Kwila Timber Stain
Resene Waterborne Woodsman penetrating oil stain tinted to Resene Crowshead
Sandpaper to fit your belt sander (we used 60, 120 and 180 grit)

Tools

Belt sander, brush, circular saw, clamps, drill, paintbrush, tape measure.

Top tip: Your pallets could be a different size from ours, and your outdoor space may fit a smaller or larger bar, so adjust your measurements to suit your garden.

Handy hint: Pilot holes are used to create an easier path for driving screws into wood and prevent the wood from splitting. Choose a drill bit that’s slightly smaller than the screw

Before you begin: Check your pallet for any loose slats and hammer them back down if needed.

How to build an outdoor bar

Step 1 Step one
Measure, mark and cut your pallet into three sections – one for the front and two shorter, equal lengths for the sides. We cut our sides at 400mm, leaving 1400mm for the front panel. Ideally, your cuts will leave vertical supports in place on each section to keep the slats held together and to have something to screw the wheels to later on (if using).

Step 2 Step two
Stand all three pieces in position and drill pilot holes along both ends of the front slat – two holes per slat.

Step 3 Step three
Using the pilot holes as guides, screw the panels together using 35mm screws.

Step 4 Step four
Cut the loose pallet slat timber to size. You will need two lengths to be the width of the inside of the bar for the shelves (ours were 1360mm), four the height of the bar (ours were 1000mm) for the corners, and two the depth of the inside of the bar for shelf supports (ours were 300mm).

Step 5 Step five
Attach the two shelf supports at each inside end of the bar 250mm up from the ground using 35mm screws, drilling pilot holes first.

Step 6 Step six
Place your two lengths of timber for the shelves in place, drill pilot holes and screw down using 35mm screws.

Step 7 Step seven - Optional
Flip your bar upside down and attach the wheels to the vertical supports using the coach screws. We put the two wheels with brakes at the back of the bar (the open side with the shelf).

Step 8 Step eight
Sand the macrocarpa slab – the top of your bar – using a belt sander. If your slab is rough like ours, use 60 grit sandpaper first, followed by 120 grit, before finishing with 180 grit. Brush off the sanding dust when finished.

Step 9 Step nine
Stain the entire bar (excluding the four corner lengths and the macrocarpa slab), with Resene Waterborne Woodsman penetrating oil stain tinted to Resene Crowshead.

Step 10 Step ten
Stain the four corner lengths of timber with Resene Kwila Timber Stain.

Step 11 Step eleven
Stain the macrocarpa slab with Resene Kwila Timber Stain. All faces of the timber should be treated, with special attention being paid to the end grains.

Step 12 Step twelve
Once the macrocarpa slab is dry, place it into position on top of the base of your bar, making sure it is centred. Secure it in place with 100mm screws from the underside, as shown.