Build Your Own Backyard Pallet Bar for Entertaining and Hangouts

The Inspiration Behind My Pallet Bar Project

I've always loved the look of cool homemade bars made from unique repurposed materials. Recently, I came across a photo on social media of a really awesome DIY pallet bar someone had built in their backyard. As soon as I saw it, I just knew I had to try making one myself. The rustic, industrial vibe of the wood pallets paired with the edgy pipe shelves really appealed to my personal sense of style.

Bars made from pallets allow you to create a fun hangout spot affordably using materials that are easy to source. Wood pallets are readily available for free or very cheap. Not to mention, upcycling and repurposing items that would otherwise go to waste aligns nicely with my values around sustainability and reducing my environmental impact.

Planning My Pallet Bar Design

Once I decided to take on this #palletproject, the first step was figuring out the overall design. I browsed various social platforms like Instagram and Pinterest for inspiration on #palletfurniture bars others have built. I took notes on elements I liked and didn't like to help formulate a plan.

A few key factors I had to take into account:

• What are the dimensions of the pallets I can get my hands on? This would determine the overall footprint.
• Should it have a cover or be open air?
• How high should the countertop be for standing or sitting?
• What materials do I want for the top surface and shelves?

After researching ideas and options, I sketched up some rough plans to visualize the #diyproject build. My design was for an L-shaped open bar using a total of 5 standard wood pallets. I decided on a 40" high countertop to accommodate both standing and sitting. For the top, I planned to join and secure several pallets to create the surface area needed, keeping the slatted texture for added style. I came up with a materials list for everything I would need to purchase including pipes, flanges and lumber.

Sourcing Pallet Bar Materials

With my #palletbar design mapped out, it was time to gather all the necessary supplies. Here is an overview of my build materials and where I got them:

• Pallets - I sourced 10 free pallets from local businesses to account for any that were too broken or damaged to use.
• Lumber - I bought 2x4s and plywood from the home improvement store for structural supports and the subtop.
• Pipes and fittings - I went to my local hardware store for black iron pipes and flanges to construct shelves.
• Bar top finish - I used a food-safe bar and countertop epoxy to seal and protect the pallet wood surface.
• Tools - I assembled my toolbox with a circular saw, power drill, nails, screws, sandpaper and safety gear.

Building the Pallet Bar Step-by-Step

Prepping and Cutting the Pallets

To start, I went through all the pallets I had sourced and set aside any that were too far gone to reuse. Out of the 10 I sourced, 5 were in suitable shape for my project. I disassembled them to begin the prep work.

Using my circular saw, I trimmed off any excess edges or protruding nails and screws. I sanded down the boards to smooth any rough spots. I also cut several boards to shorter lengths in order to assemble the front and sides how I had envisioned in my plans.

Assembling the Base

With my materials prepped, I started by constructing the base of the bar using 2x4 lumber. I cut two lengths the size of the footprint and secured them into a rectangle using 3" screws. The 2x4 base would provide structural integrity and something solid to anchor the pallets to.

Next, I laid out the pallet boards based on the measurements in my plans. I made sure the pallet slats were oriented sideways for maximum strength. Once I had the pallets aligned how I wanted, I screwed them into the 2x4 base using 3" screws about every 12 inches.

Adding Supports and Pallet Top

On the interior of the bar, I cut and attached additional 2x4 supports vertically along the walls and across the top. These would add stability and provide something to fasten shelves and the top to later on.

For the countertop, I centered and screwed a few pallets side-by-side on top of the 2x4 supports until I had the surface area I needed. I also added a plywood subtop underneath to prevent sagging.

Constructing the Shelves

To build the metal pipe shelves, I measured and cut black iron pipes to length with pipe cutters. I assembled them into rectangles using corner joints, tees and flanges. I anchored each shelf into the 2x4 supports by screwing the flanges into the wood.

I built a total of three shelves at varying heights along the back wall of the bar for displaying bottles and other items.

Finishing Touches

Once construction was complete, I sanded everything smooth. I used wood glue to fill any cracks or holes in the pallets. After some minor repairs, I applied two coats of food-safe epoxy resin on the countertop to seal and protect the surface.

To finish it off, I decorated my new #palletbar with fun lighting strands and printed signage. I loaded it up with seltzers, mixers, garnishes and bar tools.

The Final Product: My DIY Pallet Bar

After a lot of planning, collecting materials and good old blood, sweat and tears - my DIY pallet bar was finally complete! I was really happy with how it turned out. The wood pallets have such a great worn and weathered texture that pairs nicely with the black pipe shelves. It's the perfect backyard addition for hosting friends or just casual hangouts this summer.

This was my first big pallet project, and I learned so much about woodworking and bar building throughout the process. Although it required some hard work, it was super satisfying to create something awesome from recycled materials. I already have plans swirling in my head for what my next #diyproject or #palletfurniture creation will be!

FAQs

Where can I find free pallets for my project?

Check with local businesses like grocery stores, home improvement stores, warehouses, etc. Explain that you're working on a DIY project and would like to take any unwanted pallets off their hands.

What's the best way to disassemble pallets?

Use a pry bar to pop off any nails holding the boards together. You can also use a circular saw to cut through the middle of nails and break down pallets efficiently.

Should I treat the pallet wood against rot and bugs?

Yes, you'll want to clean the pallets and apply a wood treatment or sealant before building your bar. This will protect the longevity of the wood in outdoor environments.

How do I get a smooth bar top surface?

Sand the pallet boards thoroughly once constructed to smooth any rough areas. Fill cracks with wood filler and apply an epoxy resin coating to create a sealed, uniform bar top.

What can I use to decorate my pallet bar?

Get creative with fun details! Add lighting like string lights or lanterns. Use chalkboard paint to create drink menus. Paint, stain or stencil designs onto the wood. Attach hooks for hanging glassware and tools.