Outdoor Pallet Couch

Spring is here and summer, hopefully, will bring cookouts, lounging, and time with family and friends in our backyard. Last year, we only had a few cookouts, but folks had a hard time finding comfortable seating. Judy and I took a look at couches at Ikea and quickly were dissuaded by the prices. Since we are still riding this DIY kick, we took our search to the internet and quickly found a pallet couch. We estimated that we could build the couch for less than $300 (pallets, fabric, pillows, and cushions came out to $275) The original directions are a bit vague and confusing, so we decided to write out or procedure in hopes of helping folks out.

Materials/Tools
1. Circular Saw
2. Sander
3. Nine (9) 40x48" pallets
4. Five (5) 2x4x8s (optional)
5. Tape measure
6. Hammer
7. Crib Mattresses
8. Outdoor Fabric
9. Pillows

Measuring to cut the pallet

Step 1 - Size Two Sections
Judy and I looked for outdoor cushions, but we were not thrilled about $35 cushions from Ikea or $100 cushions from Home Depot. So, we opted for crib mattresses as suggested on the original blog. We hit craigslist and our friends and scrounged up three crib mattresses (under $40 for all three) and plan on making a cover for them using outdoor fabric. After that decision, we needed to size the pallets to fit the mattresses. A standard crib mattress measures 27.5" wide and the pallets that we used are 40x48". Use a circular saw to cut off 7.5" off the pallet's 40" side. We left 5" on the pallet to provide us with enough room for a back rest.
After cutting off the excess, we pried the remaining slats off of the excess piece and removed the nails from the thicker board. Then we placed the thicker piece of wood into the sized pallet to replace the part we removed.

Pallet Sized to 32.5"

Side shot of mattress and place holder
for backrest

Example of backing and mattress

Step 2 - Sizing the Chaise
The chaise is needed to be sized a little differently than the other pallets. We cut the final pallet into an L shape. The measurements are a bit tricky, but I've labeled an example below. Also, the mattress will hang about 5 inches over the pallet. But we remedied this with the next step.

Step 3 - Adding on to Chaise
Since there is about a 4 inch overhang, we needed to build a box of sorts to compensate for the 48" pallet. There are few options here: 1. build out a box using plywood, 2. use the leftover half pallet from the backrest to build out the chaise. We did the latter.

Diagram for sections 1 and 2

Diagram for L (section 3)

Diagrams of Pallet Couch Sections (Note: diagrams are not to scale)

Section 1, 2, and 3 attached
(note: overhanging mattress is not addressed in diagram)

Step 4 - Backrest
We left all the parts separate for easier storage. In other words, the pallets are not attached and back rest is simply resting on 2x4s. To make the backrests, we cut two pallets in half and attached 2x4s to the backside. We measured out 2x4s and used deck screws to attach the 2x4s to the shorter end of the pallets. Since the couch will be up against the garage, we decided simply push the base against the 2x4s to keep the backrests in place.

Guide Line for Saw

Cutting Pallet in Half for Backrest

Backrest

Step 5 - Sanding down the backrest

The pallets were quite dirty, so we decide to sand and poly them to cut down on the amount of dirt and splinters for our guests.

Judy working the sander on the backrest

Close up

Step 6 - Cushions and Pillows
What really makes this piece stand out are the cushions and pillows. Judy and I picked out some outdoor fabric from Joann's. The fabric for the cushions is outdoor fabric, but the pillows are made of canvas. We asked my mom to sew the pillow cases and cushions, so a huge thank you to her! There are tons of options for a backrest and the cushions (we kicked around the idea of using a bolster, but went with the pillows instead). We opted for the crib mattresses because they are significantly cheaper than buying $75/yard foam. We bought/found the three of our cushions for $38 on craigslist. The pillows are from Joanns too.

My buddy and I breaking in the couch

We really enjoyed this project and can't wait to share this couch with out family and friends. We'll send updates if we make anything else or notice any issues. Thanks for reading and please subscribe/share! 

If we were building this pallet couch again...

• Save some time by using 2x4s to fill in for the pallet end. We did our best and were able to salvage most of the pallet, but the time we spend on removing nails would have been better spent doing other things. So, if we ever do this again, we would definitely use 2x4s to replace those ends (the one marked with a red arrow). See picture for more details. 

Repurposed Windows to Picture Frames

Repurposing materials is all the rage right now. I particularly enjoy repurposing because its good for the environment, extremely cost efficient, and, usually, the end product is superior in quality than a new affordable product.

In search of unique ways to frame photos, Judy stumbled upon a repurposed window used as a picture frame. Immediately, we wanted to take on the project. We kept an eye out for windows, but didn’t come across any until a few months later, I pulled out of my garage on my way to work when I noticed some windows my next door neighbor tossed in the alley. Put the car in reverse, hopped out, and picked up four windows.

The following weekend, we made these wonderful pictures frames for a total of about $20:

Materials

Used window

Pictures

Fabric (measured to fit)

Tools/Supplies

Staple Gun

Staples

Drill

French Cleat or Frame hanging kit

Tape or safety pins

Pictures

Step 1: Prep Work

Dirty Windows 

The windows I found were dirty beyond belief. I did my best to scrape and scrub the frame and glass before using a solution of vinegar and hot water to further clean the frame and glass. Once satisfied, I gave the glass a once over with some Windex.

I also made an attempt at stripping the paint, but ultimately decided to keep the original for more of a rustic look.

Stripped Paint

Pinned Picture
(My Father Building an Entertainment Center circa '83)

Taped Picture

Step 2: Place Photographs

Originally, our idea was to safety pin the photographs on to the fabric. This truly tested our patience. For the second frame we opted for the more practical, but less attractive, option of using tape. This worked fine, but I’d really prefer something else. I have a suggestion of what you can do below in the “If I were going to make this again” section.

Back of Frame

Step 3: Attach Fabric with Staple Gun

At JoAnn Fabrics, my wife and I looked through various materials to use as a backing. A burlap material with a chevron print stood out to us. Another option is wall paper samples behind the photographs. Most wall paper companies will mail out free samples on their website.

Cut the fabric so it clears about an inch outside of the glass. This can be cut down later if it protrudes. Start at the corner and staple down the fabric. Continue this process until one side is stapled. Next, do the same on the opposite side, but be sure to keep the fabric taut.

Step 4: French Cleat Attachment

Cleat on Wall

One of the last steps is to attached the french cleat. Decide where to hang the piece and, if possible, hold the frame against the wall and use a pencil to outline where the top corners will be. Then measure the window to find center and note the measurement. Using that measurement and the outline on the wall, mark the center point of where the cleat should go. Put the cleat on the wall and mark where the holes will go. Be sure the cleat is level. 

Cleat on Back of Frame

Using a drill, drill suggested guide holes from the directions on the back of the product into your wall. I enjoy using OOK’s French Cleat. It is available at most big box stores and Michaels and runs about $7. Repeat this process on the window frame.

Step 5: Hang

Finally, hang the piece and enjoy!

If I were going to make this frame again...

• Recently, we took a trip to Habitat for Humanity’s ReStore. It’s a great place to search for odds and ends. I noticed they had a few old windows and doors that could be repurposed. Check it out if you’re in need of used windows.

• We tried to pin our pictures to the first window and taped the pictures to the glass on the second frame. This works well, but a complete pain to remove or rearrange the photos (especially since we stapled the fabric to the window).

• I recommend finding an alternate method of attaching the fabric to the windows. Once the fabric is stapled to the back of the window, it will be difficult to change out the photos in the future. An idea I had, but did not execute, is to upholster a thin piece of wood sized to fit the window. Then attach the photographs to the upholstered piece of wood and clip the wood behind the window with a few finishing nails hammered in at an angle. This will make it much easier to swap out photos.
  
  
  
  
  Once again, thanks for reading and following. Please share and stay tuned for our next project.