How to Turn Wooden Pallets into a DIY Outdoor Sectional

How to Turn Wooden Pallets into a DIY Outdoor Sectional

How to Turn Wooden Pallets into a DIY Outdoor Sectional

If you’ve shopped around any furniture stores lately, you’ve probably noticed that sectional sofas and couches are in. Sectional sofas come in several modules you can configure and separate at will for a range of formations. There are plenty of reasons to love the outdoor sectional. It’s versatile, trendy, practical, and minimalist. But it can sadly also be rather pricey.

Thankfully, making your own garden sectional sofa is pretty simple. It’s a great way to reuse old wooden pallets and allows you to make it as raw and rudimentary or as refined as you like.

You will need:

  • 12-15 pallets (depending on the size of your sectional)
  • Wood putty
  • Wood glue
  • Exterior wood screws
  • A sander
  • A saw
  • A drill
  • Exterior paint or wood varnish

Step 1.

Before beginning your project, arrange your pallets into the couch configuration you will use the most. Make sure it fits into the space it’s intended for. If you choose to have backrests, decide where you’ll want them to go and make sure you’re happy with their height when they stand vertically.

Step 2.

Screw each section together with wood screws and wood glue. This is going to be a lengthy project, so take breaks between each sectional and make sure you have a building partner around to give you a helping hand.

At the end of this step, you’ll have several block segments you can push together to form a couch, two couches and a table, a lounge, or what have you – but don’t configure your furniture just yet.

Step 3.

Fill in any holes in your wood with putty. This will give your furniture a more flawless look. Don’t worry too much if it gets messy because you’ll sand the wood down to a smooth finish once the putty has dried.


Step 4.

Apply a waterproof exterior paint or wood varnish. It will be easier and faster if you have a paint sprayer. Don’t forget wooden pallets have lots of awkward angles and gaps you’ll want to get into. Using a paint sprayer will give you an even finish and requires fewer coats than using a brush.

Of course, it’s also possible to paint your sectionals by hand. But I recommend calling in the troops – friends and family – to help speed up the process. (They’re sure to come if you lure them in with the promise of free beer and pizza afterwards).

Step 5.

Once the layers of paint have dried completely, you can push your couch together to see the finished product. Of course, an outdoor sectional made of pallets wouldn’t be very comfortable without a bit of padding. Choosing your cushions is also your best chance of picking a bit of outdoor décor to stylise your couch.

Since you’ve saved costs on your outdoor sectional by doing it yourself, you can always splurge and purchase outdoor cushions.

But you can also easily make them yourself. Simply buy some big foam blocks and a waterproof fabric from a fabric and crafts store. Sew the material together and stitch it over the foam blocks (alternatively you can use an adhesive spray to stick it onto the foam).

That’s all there is to it! Invite the friends over for a BBQ (or that pizza and beer you promised) and test out your new DIY piece of outdoor furniture.


How to Turn Wooden Pallets into a DIY Outdoor Sectional

Photo credit: Mike Mozart via Flickr.


If you’re looking for more easy and inspiring DIY ideas, check out the Love Life Outdoors Blog.

Alex is the National Brand Manager at Australian Outdoor Living. She loves her job and loves jotting down her thoughts on all things outdoors.

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