How To Make A Pallet Deck Chair

In this DIY video from Bosch, big wave surfer Mark Visser demonstrates how to build a deck chair from an old hardwood pallet.

In this DIY video from Bosch, big wave surfer Mark Visser shows how to build a deck chair from an old hardwood pallet.

Click here to get the full step-by-step instructions for this project

Click here to download the project PDF

The first step to make this chair is to disassemble a pallet. Pull all the boards apart with a hammer or prybar and remove all the nails.
 
Use the pallet slats as the seat boards, and use the frame pieces for the frame of the chair. Cut all the pieces to size with a mitresaw and use a planer to create a pencil edge on all the pieces, then sand smooth.
 
Create the sides by securing the seat rail to the legs using a drill driver, then attach the armrest. Secure the backrest to the legs, notching the armrest to fit.
 
Secure the seat boards to the rails, leaving a 20mm overhang and spacing them evenly. Secure the back boards to the backrest, leaving a 25mm overhang at the top and spacing them evenly.
 
Trim any sharp edges and sand all over to complete the deck chair.

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