Today I’ll share with you a step-by-step guide on how to actually make a patio pallet sofa. I’m not an expert on DIY pallet furniture, so there may be other ways to achieve a similar look. But this is what worked for us, was quite cheap and not too complicated. By cheap I mean 2 dollars a pallet plus the price of cushions. And they can vary a lot in price, from 30 up to 100 dollars each, so it’s really worth looking around. Our idea was to build a pallet sofa with minimum assembly possible, using off-the-shelf cushions and used pallets. It was also really important to make them easily storable for the winter. That’s why my husband had decided that he’ll make them without permanent fasteners.
Here is what we used for 2 sofas:
Outdoor seat cushions
Extra wood (2×4)
We started with measuring our cushion size, they were 24″ by 24″. We wanted our seat to be slightly inclined that’s why we left enough space to fit the back of the sofa :
The pallet size was 48″ by 40″, the perfect size for a two seat sofa (2 times 24 is 48). So we didn’t have to cut it on one side. On the side that needed trimming we added the 5 ” for the back rest and we have cut our pallet to the 48″ by 29″ size.
In the typical pallet structure the studs are oriented toward the longer side, that’s why we had to remove one of the studs and replace it with a 48″ long 2 by 4, and nailed it at each plank. That way it could hold the back rest of our sofa. We did so for every pallet we used for the seat. Since we wanted more of a lounge seat, we used only two for each sofa.
Then it was time for the back rest. For that we turned the pallet in the other direction that the one we used for the seats. That meant it would be a bit more narrow than the seats (4 inches shorter on each side) but was fine for us. We trimmed the three studs to 30″ to have the proper back rest height.
And we removed a few of the planks to allow the back rest studs to insert in to the seat. We also had to cut a couple of planks and trim the central stud of the back rest.
To assemble the sofas we stacked two seat pallets together, and then we inserted the back rest in between the seat studs.
And here it is,ready to chill and relax, with the cushions from Home Depot, flowers and a Ikea rug :
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