Ugly Pallet Window Seat

Here is my first attempt at a build thread and a pallet creation so please be patient.
I receive a fair amount of stuff at work on pallets so I decided to keep a few throughout the winter for a few projects I have been wanting to tinker with so this weekend was the weekend to start.

I didn't really have any set dimensions of what I wanted to finish with other than some standard heights and such that I deal with in my job. (Kitchen and Bath Design/ Counter Top Shop)

I started with a Plywood core for a base which I laminated up with some scrap laminate. I also made side panels out of scrap laminate as well, that's why it is a different color than the floor a couple pics from now

Next, I squared up my base on my beam saw, so I know I am working with something square from the start and with clean edges.
Next I of course tore apart a whole bunch of pallets and found the easiest way is to cut between the slats and runners with a sawzall and metal blade and just leave the majority of nail heads.

I then took a couple of solid pieces from a heavy duty pallet approx 2" x 2" and glued and nailed them to my base


I figured out my thickness of slats and plywood on the sides and and set back spacers and nailed them to the uprights to hold my plywood at a specific depth to flush out my sides.
When I was done, I had my assembled box with laminated interior and the exterior was spaced to fit approx 1/2-5/8" slats.



I then went around the box and used a dark min wax to stain the boards dark so that any gaps between my outer slats would not show the raw wood beneath.


I then went and started dryfitting and adjusting slats to the outside for fit and coloration on where the most exposure is going to be in my house. As I get a side I like, I glue it up and nail it.

I continue around the box until it is done on all four sides.


Between my base being "perfect" and trying to fight a couple boards along the way, I am only a 1/16 out of square across the approx 36" x 18" box, I was pretty surprised by that with the rough cut pieces I was using.

More pics to come in a few mins.

 

I then stained the top edges of the plywood and began to cut a " cap piece" for around the top edge. Also below it on the back I put solid pieces where my hinge is also going to be mounted for some extra meat to screw into.


Then I attached the hinge to my box then to a piece of plywood to fit inside the box.


I stained the edges and tops and bottom of the board and attached slats to the top and an overhanging piece on the front as a "handle".



here is a pic of my last piece of the top and "handle" you can see the shiny side of the nails I cut off. I tried to leave as many rusty ones on the outside as I could.


Next I attached more slats to the inside to cover the plywood on the bottom side as well.


Finished Box ready for finish.



Not wanting a shiny finish and not worried about brush strokes on this item, ( I am used to perfectly smooth finishes on cabinetry so I am used to spraying laquer to mimic catalyzed clear coats on our brand's factory finishes.) I used this water base matte finish with a cheap brush.


You can see the right side is done and is definitely bringing out some character.

 

A couple more coats on everything and here it is.

Also, before someone points it out, I know you will see the plywood at the base when it is in the room. What I did that barely shows on one of the photos is poly'd a couple of 2 1/2" boards to match. I am going to put it in the house and make sure it is level. If not I have screw adjustable leveling legs that I can attach to the bottom and be able to screw the corners individually and level. Then I will attach the "base board" pieces around the base and cover everything else up and have the base level to the floor. I laminated the interior so that it was easily cleaned with muddy boots and so water won't absorb and discolor anything. I used silicone on all the seams as well on the inside. All in all, this took me about 3 1/2-4 hours and about $15 in finish, but I have a "free" shop with plywood scraps and equipment that saved me a lot of time that most people don't have, so your mileage will vary. Up next in a few days is the entertainment center I am hopefully finishing tonight.

-Chris

 

My house is pretty open to this style. Also, I have a log cabin, so if I don't like it here after a while, I have more options instead of just getting rid of it. I am curious to get it in my house and see if maybe end tables will be next project to go with the window seat and entertainment center.

But I have to find some more pallets. All my decent colored ones are used up. I just have brand new bright clean pallets left.

 

Torch. I tried a piece with stain it it just turned almost black and the stain I didn't think was all that dark In the list of Min wax. Almost have to stain then hit with a grinder and then the torch in spots. Or just wait for more pallets that are already all stained up. That will be easier.

 

Just put them outside...they'll get a patina on them pretty quick.

I have shop envy.

 

Some of the best colored pallets I used were from pellets that of course sat outside for who knows how long.

The shop is much larger than I usually ever need but I have it and the building has been paid for forever so it just costs utilities and taxes. The shop section that were in a couple of the pics is about 30' x 125'. I am thinking of knocking down another wall that used to be an office to add a bit more but rarely do I ever need what I have now. We have gotten away from some of the fabrication/ finish work we used to do in house years ago, but when I need a tool, it is nice to have all the equipment sitting there and in quantities. I think of selling stuff sometimes, but then I get a use for an 6' bar clamp and I have 20 of them on hand, so I always end of thinking about the "someday I may need this again" situations.

 

I don't think it is ugly. Just perfect for the right setting.

 

Nice job Chris.
Hard to go wrong with your experience and all the gooder tools at hand.
I like the beam saw......is it tough to keep square?
Is it adjustable for angle cuts? I'm intrigued.

 

The aluminum pieces are the guides. Each side locks at 90/ 45/ 22 1/2. The saw is about 1/64th out of square in about 8' which for my business is well beyond good. The saw is great for doing mitres and having 2 "perfect" pieces to match up at seams in counter tops

 

I don't have the base board around the piece yet (or in most of the house right now) but here it is sitting in place. I have a coat rack/ storage cabinet that will be hung above. I will get a finished pic when everything else is finished up too.

 

I have been stockpiling some more pallets since my last projects and had some time this weekend so I went ahead and made a coffee table and end tables. Not as in depth of a build but here are some pics.

 

The white on the boards in spots is because the pics are right after I finished brushing on the finish and it is wet

 

Water based Poly?