Step-by-step Guide On How To Build A Pallet Bar On Your Own

Pallets are famous for making garden furniture, upgrading your patio, and making indoor creations, like pallet sofas. But did you know that you can also build your own pallet bar in no time? You can use wood pallets to create a bar area at home or your garden without stretching your budget with expensive purchases.

wooden pallets

You can find wood pallets easily, and they are easy to work with. Do you worry that pallet bars are just inexpensive and easy to construct at home? We have some amazing news! They are durable and sturdy and add warmth and texture to your place, thanks to their hardwood essences! Follow our guide to learn how to build a pallet bar, and enjoy your favourite drinks with your friends and family. All your guests will fall in love with your house!

Why build a pallet bar?

Does having a DIY outdoor bar in your back garden or one in your house sound fun to you? It definitely is! But that is just one of the many benefits it has. Here are all the reasons why you should build your own as soon as possible.

  1. Reclaimed wood is a high-quality “upcycled” wood that you can use for many wooden pallet furniture designs ideas and DIY projects. By upcycling, you can save not only money but also the planet.
  2. Having your own bar at home, you can host any kind of celebration, any time! Remember; there are many occasions to celebrate throughout the year, and you can make them extra special when arranging the parties yourself!
  3. Do you love trying new drinks and cocktails? Having a bar gives you the excellent excuse to bring out the hidden mixologist inside of you!
  4. You can save money when you have a night at home with some drinks whilst meeting friends in a bar or pub instead. You can have the same fun without having to worry about the bill!
  5. It is an excellent addition to your garden, but also any room in your house, and most importantly, in a game room or man cave!

Tools and materials you’ll need for your project

As with all DIY projects, it is essential to have all you’ll need handy. That will help you avoid any mistakes but also save you time! Below are all you’ll need for your bar design:

  • Circular saw
  • Combination square
  • Drill
  • Drop saw
  • Earmuffs
  • Hammer
  • Handsaw
  • Impact driver
  • Nail gun
  • Orbital sander
  • Measuring tape
  • Paintbrush
  • Pencil
  • Putty knife
  • Quick clamps
  • Safety glasses
  • Work gloves
  • 90mm x 45mm treated pine
  • 1500mm x 90mm treated pine decking boards x 9
  • Wooden pallet
  • 75mm bugle or wood screws
  • Timber varnish
  • Putty
  • Sandpaper

Construction Worker Using Drill To wood.

How to build an indoor or outdoor pallet bar

Are you ready for your DIY pallet bar project? You’ll be surprised to know what you can do with 2 old pallets and some timber. Follow our tutorial for a rustic-looking bar that will look great in your backyard or your home when you’re entertaining friends and family. Here are all the step-by-step instructions you’ll need!

Step 1: Measure and mark the halfway point on the recycled pallet

  • Start your project by cutting 1 of the pallets in half to make the 2 sides for your bar.
  • Measure and mark the pallet’s centre point, where you’re going to cut. 
  • Turn the pallet over and measure and mark the centre point on this side too.

Step 2: Cut your pallet in half

  1. With the circular saw, cut one side of the pallet in half
  2. Turn the pallet over and then cut the other side
  3. You can also use a handsaw to do the job. Always remember to wear your safety gear while using the circular saw.

Step 3: Measure and mark the 45-degree mitre cuts

Stand your pallet on its side and then use a set square to measure and mark 45-degree angles at the pallet’s ends you’ve cut.

Step 4: Cut the ends of the pallet

Using the circular saw, make the cuts where you’ve marked. Keep in mind that an extra pair of hands can be beneficial to balance the pallet. If you want to make sure you don’t hit any nails when making your cuts, you should remove any boards that will be sawn. You can easily replace them once you’ve made the cuts.

Step 5: Measure and mark for your supports

The supports are the fixing points for your garden bar. Measure the size of the gaps in your pallet, and then transfer those measurements onto your 90mm x 45mm treated pine.

man measuring pallet with measuring tape

Step 6: Cut the supports with a drop saw

Using the drop saw, cut the timber for the supports to length.

Step 7: Secure your supports

Using a hammer, knock the supports into place. Then, pre-drill the holes with the 5.5mm drill bit and fix the supports into place with your 75mm bugle screws.

Step 8: Join the pallets together

Once you get the supports in place, you should join the pallet and the 2 halves together to make the bar’s base. Using a 5.5mm drill bit, pre-drill the holes and then drive the 75mm bugle screws into the treated pine supports to join your 3 pallet pieces together.

Step 9: Measure for the decking supports

The decking supports are attached to the pallet frame’s front and back, helping to support and straighten the bar frame. Measure each side of the pallet frame’s top and transfer the measurements to the timber decking.

Step 10: Cut the decking supports

Using the drop saw, cut the decking supports to size.

Step 11: Attach the decking supports to the bar

With the fixing gun, attach the supports to the pallets’ front and back.

Step 12: Measure and mark for the hardwood bar top

Measure the 3 pallet frames’ lengths and transfer those measurements onto the hardwood timber for your bar top.

Young man assembling wood pallet

Step 13: Cut the slats for the bar top

For the bar top to follow the contours of the bar frame, the 3 pieces of hardwood timber will need a combination of straight and 45-degree mitre cuts. Set your mitre saw to 45-degrees and cut the 2 shorter pieces of wood to size. Then, cut the piece of timber that is attached to the bar’s front at 90-degrees.

Step 14: Fit the front piece of timber

  1. Put the piece of timber for the bar’s front into place. 
  2. Leave a lip at the front and a 50mm overhang at the back. 
  3. Pre-drill holes with a 5.5mm bit.
  4. Countersink with a 16mm spade bit. 
  5. Use your 75mm bugle screws to fix it into place.

Step 15: Measure and mark for the timber’s side pieces 

  1. Place the timber’s side pieces for the bar top in place, leaving a 50mm lip at the back.
  2. Follow the bar’s line at the front and make 45-degree pencil lines straight across with the square so that the timber matches the bar’s shape.

Step 16: Cut the timber

Using the drop saw, cut the edges of the 2 timber pieces at 45-degrees.

Step 17: Attach the bar’s tops 

  1. To attach the bar’s tops, first place 1 of the side pieces in place. 
  2. Use a 5.5mm bit to pre-drill a hole.
  3. Countersink with a 16mm spade bit. 
  4. Screw into place using the 75mm bugle screws. 
  5. Repeat this process to fix the other timber piece to the bar’s top.

Step 18: Putty the holes and joins

  1. Using wood putty, fill the screw holes and any gaps in the joins at the top of the bar
  2. Let the putty dry thoroughly.
  3. Sand it to create a smooth surface. Use 40-grit sandpaper to flatten out the lumps and then 240-grit sandpaper for a smooth finish. 
  4. Wipe away any dust.

Step 19: Varnish the top of the bar

  1. You may paint or varnish your new wooden pallet bar to suit your style. Keep in mind that you may need to apply several coats. It is essential to let each one dry before lightly sanding and applying your next coat each time. 
  2. Also, if you want to seal the integrity of the wood for a long time, use wooden oils, epoxy resins or polyurethane treatment
  3. To personalise your bar, you may also add a drinks shelf by following the process of creating the tabletop.

paintbrush on wooden surface

Step 20: Relax at your new bar

You now have your new pallet bar ready! Relax and enjoy it with yourself, friends and family. Its rustic look will always be a good conversation starter!

Amazing decoration ideas for your pallet bar

Are you looking for some extra pallet bar ideas to personalize your pallet project? Here are some great ideas to make the most of your new bar!

  1. Add a bar sign. You can purchase a ready-made, or even order one just the way you imagine it to be.
  2. Add some greenery around your bar. If you have any existing palm trees in your outdoor space, take advantage of those to create a cool Tiki style bar.
  3. You can create a rustic yet modern look by staining and varnishing only the bar’s countertop and shelves. Leave the rest of it with its natural rustic tone of wood!
  4. Create an ample space at the back of the bar to keep your food, drinks, ice buckets, bottle openers, tableware and table napkins. Having a large storage area helps you keep your bar clean and neat.
  5. Besides adding some bar stools, setting up a BBQ grille next to your bar will make for the ultimate combination, and all your guests will enjoy it to the fullest.
  6. Add a new paver floor or patio around your bar. For your pavers, you can also use reclaimed wood to match the bar’s look.

Homemade pallet bar with pineapple lights
Are you excited about your new bar? Our DIY tutorial design is perfect for a home bar or a backyard or patio. This is an easy design that doesn’t require expert woodworking skills and talents. All you need to do is follow our instructions to create your own pallet bar. Not only will your guests love it, but the pride you’ll feel from your project will make those beverages even tastier!

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