Hi, I'm Craig Phillips in this video I'm going to show you how to build your own chair using
recycled pallet wood. And the tools you're going require a chop saw or a handsaw drills,
screws, tape measure, clamp set square and an orbital sander.
Now once you've decided the size of your chair you can start to build one section
of the frame. So I'm going to place that to one side and start to cut myself clips apart
starting off with the longest length is 900. I'm going to cut this square to start with
and then kind of create a triangle end on them to finish the top section off.
We can adjust the chop saw to cut them at 45-degree angles if you haven't got a chopped
short of course you can achieve that on your normal handsaw as well. Turn that over same
again, okay so one sides a little bit higher than the other because as we come up later
on with the laterals one of them meet and the other one sits on top of them like this.
The next stage is we want to come across 480 millimeters so we'll take one of these.
I'm going to cross it over onto the back leg at the moment I'm going to measure across
there at 480. It this piece is going to do here and of course we want it 480 for the
height which is this section here
so now by placing them three pieces of wood we can start to see the shape that we've go.
We've got the back, the seated area and then the height of what the seat sits at because
this is only one piece of timber. This is not going to be strong enough to make a frame
up like this we want to double it up and sandwich these together so the next stage is you want
to cut a piece of timber from here to here and also another one from here to here and
from there to there. Okay so that now is a double layer of the
frame that we want to achieve on there all we have to do now is glue it and screw it
all together. The position let's place back down on top lining up the peaks, squaring
them back up again screws in that side these are all about 40 millimeter screws because
the timber itself is about 20, 22 millimeters thick it's going right through the first piece
ripping into the one below again just double-checking, you keeping it squared at all times before
you drive the screws in. Okay so that is one more side of it complete
now if my measurements serve correctly we should marry up on top of them nice and square.
Perfect, so now all we've got is the two side sections of the chair built up. All we need
to do now is cut more pallet slats to bridge across between them to make the seat.
Now the width of your chair is for you to decide on but I've chosen to go 440 millimeters
I've caught a selection of timbers that are going to be fixed across one side of the frame
to do the other. Now working on your own can be a little bit tricky so what I've done
is screw a couple of blocks into the workbench here and then screw the bottom of the frame
in there and that just holds them upright for me.
As always we put plenty of glue on any sort of furniture that's taking anybody's weight
then we start to fix our slat across the first one I'm going to apply flush to the very edge
of it here a couple of pallet holes stop the wood from splitting
and again I'm driving 50 millimeter nails in nice and deep. Before I put that second
one in I'm going to do the one the opposite side here and just make sure I'm getting it
nice and square. Yeah I'm happy with that that's nice and
square. Perfect, the next lot I'm just going to place down for now before actually screw
it in because I want to create a little small gap in between each of the seat slats and
of course if you've screwed them down you've committed to them then so we'v e jus placed
them, yep that's working quite well. A couple of millimeters yeah once you're happy
with that and then you can start to fix all of them down. Now I've just put one screw
in each timber in there for the moment I'm going to put two on it I'm going to do the
opposite side now before I continue fixing that side down again just double-checking
that you've got the same size gaps between them and then you can get a fixing in the
opposite side. Okay so that's the base the seated area
of the chair now complete what I'm going to work on now is cutting more slats the same
size and working it up across back. So this is the back slat now it should be
fixed on the back here. Now again we want to create small little gaps in between them
but what I have done is cut little chocks then I'm going to slide underneath because
I’m working upwards you've got a tendency of slipping down.
These are about 10 millimeters so I'm putting 4 along here 10 millimeters in between each
one of them just about take me up to the top but before I do I'm going to drill all the
clearance holes with a pallet drill bit. Again plenty of glue, making sure again
it's flushed to both sides and if you're happy with that you start to screw him down. We'll
put two in these but I'm just going to continue getting the rest in place to double-check
that they all fit before we put the second screw in each side.
Looking well and then you can commit with your second screw and then okay so that's
more or less the back complete except I've got to fear that slat again 440 millimeters
and remember earlier on we cut these on a bit of a peak so I'm going to place my chalk
back underneath that top one. I'm going to glue and screw that one into position and
then also I further one on the back it all helps the destruction and the strength of
the chair but it just finishes off that little peak for us and then when we sand this down
later we can take off any harsh edges there as well with the sander.
Drill some pallet holes, plenty glue although to make it a bit easier because it's a bit
tall there now and I'm not the tallest of people. So I'm going to start my screws off
halfway through the wood this way it makes it a little bit easier. Here we go always
double checking flush both sides. And then we can commit a screw there to hold it
and then the one on the back of course you don't need to put any packs in there a little
bit of glue so that's now the back and the seat all fixed into position.
The next stage is to reinforce the bottom of the legs now bracing the legs is very important
because if there's any weight on here what you don't want is the legs to force out all
to force in there> So of course you can just fix battens to the front of them, screws them
in and that would be strong but aesthetically it doesn't look that good.
So what I'm going to do is maintain my joints 45 degrees so when they go together there's
a nice snog and strong joint and we do this by taking our measurements across, getting
our set square drawn on it 45 degrees there 90 off that way and turn over finding bottom
of that mark and then again 90 on there. Now, I'm going to chop these on the chops
or of course if you don't have a chop saw you can put them in your workbench then with
your handsaw. Okay so that's now our corners all cut and
mitred at -90° they will fit in between there quite well. So we start off by fixing this
one down I want to place it in the middle of these two back legs there. I'm going to
mark it then I'm going to drill some pallet holes and place this into position with the
screws. Now I'm going to put that probably about
70 or 80 millimeters off the bottom of the leg itself, okay so that's one in. Now I'll
take my tape measure I can measure it from the bottom it's coming up about 150 millimeters
and I'll do the same again from the bottom back of this leg. Now this next piece is now
going to be fixed into that mitred area right in there. So again what we want to do is get
plenty of glue behind and drill a couple of pallet hole to be able to do a fixing from
there into this timber. Turn on the side that way we drill a little bit of an angle into
here. Sometimes drilling them you have to start
off upright and then just turn the drill as you go down on an angle. Plenty of glue on
that joint. There it is nice and tight, okay. Put the screws in here they're going to shoot
in on that angle that we drilled and catch that timber that's already fixed in place.
You do exactly the same around all the rest of the three legs. Now the four main braces
are in holding all four legs together for extra precaution I'm just going to place another
one right in the very center here. Place that more or less ithe very center
if you unsure double-check with your measurements; 180, 180 perfect.
When it's in position you can drill some pallet holes from the outside and drive your
screw in to hold it into position. Now that is real solid now.
The last thing just to finish thing just finish the entire chair off is a piece right
across the front. Now that's the entire structure of your chair built, all you need to do now
is sand it down. Unscrew that and lift it away from the jig.
And that's how you make your chair out of recycle pallet wood and I've got to say they're
extremely comfortable. If you want to see some more video tips on pallet projects please
visit the website, silverlinetools.com