How to Make Wood Pallets

Wood Pallet Diagram

If you have a need for storing and transferring large quantities of material for a small business, home, farm or ranch, you might consider using wooden pallets to help you keep things organized and orderly. Pallets keep stock elevated from ground moisture, and serve as a stable base for stocking or stacking goods. A standard 40 by 48-inch pallet has cutouts on the bottom edges of the sides that allow the prongs of a forklift or pallet jack to slide underneath before hoisting and moving the stack. You can build your own sturdy, reusable wood pallet following the steps outlined here. The diagram, complete with measurements, can be enlarged by clicking on the small icon. (The measurements given here are the actual dimensions of lumber as it is purchased. Treated and aged boards are often named for the rough-cut dimensions the stock has before the surface is milled smooth.)

Things You'll Need

• Hardwood lumber stock: (8) 3.5 by 48 by 0.625-inch boards (4) 5.5 by 40 by 0.625-inch boards (3) 3.5 by 48 by 1.375-inch Boards Nails: 2.25-inch helically threaded or twisted shank

Instructions

1. Fashion the "stringers," which are the three 3.5 by 48 by 1.375-inch supports that run the length of the pallet. (Commercial pallet manufacturers use "new lumber," which is basically untreated green lumber.) Cut out two forklift notches from each stringer, starting 6 inches in from the ends. Cut out a section 9 inches long with rounded corners. Cut the round corner at a radius of 0.75 inches. (What is commonly called a 2 by 4 can be used for the stringers.)

2. Assemble the bottom deck of the forklift by nailing two 5.5 by 40 by 0.625-inch crosspiece boards, mounting one flush with each end of the two outside stringers. Nail the third stringer parallel to the others in the middle. Use nine nails per 5.5-inch crosspiece, three at each joining. Then fasten three 3.5 by 48 by 0.625-inch crosspiece boards, one in the center of the stringers and the other two just to the inside of the forklift notches. Use six nails per each 3.5-inch crosspiece, two at each joining. (Boards commonly called 1 by 4s and 1 by 6s can be used for the crosspieces.)

3. 

   Turn the pallet assembly over and fasten the boards of the top deck. Nail two 5.5 by 40 by 0.625-inch cross boards, one flush with each end of the stringers. Use nine nails per 5.5-inch crosspiece, three at each joining. Then fasten five 3.5 by 48 by 0.625-inch crosspiece boards, one in the center of the stringers and the other four evenly spaced between the middle crosspiece and the end crosspieces. Use six nails per each 3.5-inch crosspiece, two at each joining. With a rough sanding of the top deck, your durable homemade pallet is ready for a long term of service.

Tips & Warnings

• If you intend to ship stock on homemade pallets off of your premises, make sure you check local, state, national and international requirements, laws and ordinances depending on the final destination of your shipment. There may be standards, ordinances or laws with specifications that you will need to meet before moving stock on your pallets from your property.