D.I.Y. wooden pallet wine bar

D.I.Y. wooden pallet wine bar

Nick, Team member
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D.I.Y. wooden pallet wine bar

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Project Overview

It’s amazing what you can do with two old pallets and some timber. This rustic-looking pallet bar will look great in your backyard or your home when you’re entertaining family and friends. We’ll show you how to make one in a few simple steps. Continue to step-by-step instructions
removing bent nail
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How to remove a bent nail

If a nail bends as you hammer it in, don’t try to straighten it, just remove it. The easiest way to do this is to place a thin piece of timber beside the nail to support the hammer and protect the surface. Fit the claw of the hammer under the nail head and pull the handle towards you until the nail comes out. Keep the handle as close to vertical as possible so you don’t make the nail hole wider.

Step by Step Instructions

1 Measure and mark the halfway point on the pallet
2 Cut the pallet in half
3 Measure and mark the 45-degree mitre cuts
4 Cut the ends of the pallet
5 Measure and mark for the supports
6 Cutting the supports with a drop saw
7 Secure the supports
8 Join the pallets together
9 Measure for the decking supports
10 Cut the decking supports
11 Attach the decking supports to the bar
12 Measure and mark for the hardwood bar top
13 Cut the timber for the bar top
14 Fit the front piece of timber
15 Measure and mark for the side pieces of timber
16 Cut the timber
17 Attach the tops of the bar
18 Putty the holes and joins
19 Varnish the top of the bar
20 Relax at your new bar

  • Step 1. Measure and mark the halfway point on the pallet

    Start this project by cutting one of the pallets in half to make the two sides for the bar. Measure and mark the centre point on the pallet where you’re going to make the cut. Then turn the pallet over and measure and mark the centre point on that side as well.
    Previous Step Next Step
    Measure and mark halfway point on pallet

  • Step 2. Cut the pallet in half

    Use the circular saw to cut one side of the pallet in half. Turn it over and then cut the other side. If the circular saw doesn’t cut all the way through, you can use a hand saw to finish the job. Don’t forget to always wear your safety gear when using the circular saw.
    Previous Step Next Step
    Cutting pallet in half with a circular saw

  • Step 3. Measure and mark the 45-degree mitre cuts

    Stand the pallet on its side. Use the set square to measure and mark 45-degree angles at the ends of the pallet you’ve cut.
    Previous Step Next Step
    Measure and mark 45 degree mitre cuts

  • Step 4. Cut the ends of the pallet

    Use the circular saw to make the cuts where you’ve marked. When cutting the mitres, an extra pair of hands can be helpful to balance the pallet. A good tip to make sure you don’t hit any nails when making the cuts is to remove any boards that will be sawn. These can be easily replaced once you’ve made your cuts.
    Previous Step Next Step
    Cut the ends of the pallet

  • Step 5. Measure and mark for the supports

    The supports are the fixing points for your bar. Measure the size of the gaps in the pallet, and then transfer these measurements onto the 90mm x 45mm treated pine.
    Previous Step Next Step
    Measure and mark for supports

  • Step 6. Cutting the supports with a drop saw

    Use the drop saw to cut the timber for the supports to length.
    Previous Step Next Step
    Cutting the supports with a drop saw

  • Step 7. Secure the supports

    Use a hammer to knock the supports into place. Pre-drill the holes with a 5.5mm drill bit. Then fix the supports into place with the 75mm bugle screws.
    Previous Step Next Step
    Securing the supports with screws

  • Step 8. Join the pallets together

    Once the supports are in place, it’s time to join the pallet and the two halves together to make the base of the bar. Pre-drill the holes with a 5.5mm drill bit and then drive the 75mm bugle screws into the treated pine supports to join the three pallet pieces together.
    Previous Step Next Step
    Joining the pallets together

  • Step 9. Measure for the decking supports

    The decking supports are attached to the front and back of the pallet frame, helping to straighten and support the bar frame. Measure each side of the top of the pallet frame and transfer these measurements to the timber decking.
    Previous Step Next Step
    Measuring and marking for the decking supports

  • Step 10. Cut the decking supports

    Use the drop saw to cut the decking supports to size.
    Previous Step Next Step
    Cutting the decking supports with a drop saw

  • Step 11. Attach the decking supports to the bar

    Use the fixing gun to attach the supports to the front and back of the pallets.
    Previous Step Next Step
    Attaching the decking supports to the bar

  • Step 12. Measure and mark for the hardwood bar top

    Measure the lengths of the three pallet frames and transfer these measurements onto the hardwood timber for the bar top.
    Previous Step Next Step
    Measuring and marking for the hardwood bar top

  • Step 13. Cut the timber for the bar top

    The three pieces of hardwood timber will need a combination of straight and 45-degree mitre cuts so that the bar top follows the contours of the bar frame. Set the mitre saw to 45 degrees and cut the two shorter pieces of timber to size. Cut the piece of timber that is attached to the front of the bar at 90 degrees.
    Previous Step Next Step
    Cutting the timber for the bar top

  • Step 14. Fit the front piece of timber

    Put the piece of timber for the front of the bar into place. We left a lip at the front and a 50mm overhang at the back. Pre-drill holes using a 5.5mm bit, then countersink using a 16mm spade bit. Use the 75mm bugle screws to fix it into place.
    Previous Step Next Step
    Man screwing the bar top to the pallet frame

  • Step 15. Measure and mark for the side pieces of timber

    Place the side pieces of timber for the bar top in place, remembering to leave a 50mm lip at the back. Follow the line of the bar at the front and make 45-degree pencil lines straight across with your square so that the timber matches the shape of the bar.
    Previous Step Next Step
    Measuring and marking for the side piece of timber

  • Step 16. Cut the timber

    Use the drop saw to cut the edges of the two pieces of timber at 45 degrees.
    Previous Step Next Step
    Cutting the timber

  • Step 17. Attach the tops of the bar

    Place one of the side pieces in place. Pre-drill a hole using a 5.5mm bit and then countersink using a 16mm spade bit. Screw into place with the 75mm bugle screws. Repeat this to fix the other piece of timber to the top of the bar.
    Previous Step Next Step
    Attaching the tops of the bar

  • Step 18. Putty the holes and joins

    Use wood putty to fill the screw holes and any gaps in the joins at the top of the bar. Let the putty dry and sand it to create a smooth surface. Start with 40 grit sandpaper to flatten out the lumps and finish off with 240 grit sandpaper. Wipe away any dust.
    Previous Step Next Step
    Puttying the holes and joins

  • Step 19. Varnish the top of the bar

    You can paint or varnish your bar to suit your style. We used an exterior grade varnish so it can be left outside. You might need to apply several coats, so let each one dry before lightly sanding and applying the next coat. To personalise your bar, you can also add a drinks shelf by repeating the process of creating the bar top.
    Previous Step Next Step
    Varnishing the top of the bar

  • Step 20. Relax at your new bar

    Your new pallet bar will look great in its place in your backyard or inside your home; and its rustic look will be a good conversation starter.
    Previous Step Next Step
    completed pallet bar in backyard

Tools and Materials

Tools

  • Circular saw
  • Combination square
  • Cordless drill
  • Phillips bit
  • 5.5mm hex screw bit
  • 16mm spade bit
  • Drop saw
  • Earmuffs
  • Hammer
  • Handsaw
  • Impact driver
  • Nail gun and brads
  • Orbital sander
  • Measuring tape or ruler
  • Paint brush
  • Pencil
  • Putty knife
  • Quick clamps
  • Safety glasses
  • Work gloves

Materials

  • 90mm x 45mm treated pine
  • 90mm x 19mm treated pine decking
  • 1800mm x 600mm x 26mm hardwood utility panel x 2
  • Pallets (of the same size) x 2
  • 75mm bugle screws
  • Exterior varnish
  • Putty
  • 240, 120 and 40 grit sandpaper
  • 5

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