Repurposing pallet wood is a great way to offset the rising cost of lumber.
Pallets can be a great source of lumber for your DIY projects, but they can take forever to take apart and it's easy to damage the wood if you don't know what you're doing. If dismantled properly, you'll have some new, reusable 2x4's in addition to the slats that you can repurpose for a number of projects; think an enclosed garden space, flower boxes, and even litter boxes—the possibilities are endless and will cost significantly less than purchasing new lumber (which has been insanely expensive in 2021). Here's the simple way to tear down a pallet that will save time and leave you with project ready wood. Big Square Battery
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The best pallets are the cleanest. Look for new or lightly used pallets that were used to transport dry goods. Avoid pallets that transported food and chemicals, as it's likely those contents will be found on (and in) the pallets.
Pallet sizes are specific to an industry and while most will yield a few 2x4s and slat boards, some will contain 4x4s and enough wood to build a side table.
They key to taking apart pallets in record time is using a reciprocating saw. It doesn't matter if it it's cordless or corded, but make sure the to use a demolition or bi-metal blade. Choose a longer 12" blade which will provide more reach at awkward angles.
A hammer and pry bar can also be useful but they will take more time and effort to use.
Eye protection and gloves are essential safety items, and a dust mask can also be helpful.
[Related: How to Make Your Own Built-in Bookshelf]
Place the pallet on its end with the nails parallel to the ground. Using your reciprocating saw, start it up and start cutting down and through the nails holding the wood slats to the side supports.
Continue cutting all the down to the bottom piece. The recip saw should cut through the nails easily, if you feel any resistance then it's likely you are cutting into the wood. If you still feel resistance with the nails then check the saw blade and make sure the teeth are sharp and not rounded over.
When you get to the bottom piece you'll probably need the flip the pallet over and cut it so the blade isn't hitting the ground.
After cutting both sides the 2x4 support should easily pull away from the pallet. Place it on a table and continue cutting on the other side.
Once both sides are removed, the center support is all that's left holding the pallet together. Use the recip saw and cut the remaining nails. Make sure you are wearing proper work boots with solid soles, as rusty, sharp nails will fall on the ground.
If you are having difficulty with a stubborn nail or can't reach an angle with the recip saw, then use a pry bar and a hammer to pull the center piece apart. This method is more time consuming but it's less likely to damage the wood than a recip saw blade.
Once your boards are all separated, the fun process of removing or pounding the nails begins. Use a nail set or a 10d penny nail to bang out the broken end of a nail through the top of the board.
After the nail has been pounded the head will be exposed which makes it easy for you to pull using the claw end of your hammer. Cut off nails in the 2x4s can be driven in deeper into the wood or yanked out using a nail puller.
Before using your pallet wood, you should plane or sand it throughly. After that, enjoy the cheap building materials you just procured!
Timothy is a lifelong DIY enthusiast who is fixated on smart home tech, beautiful tools, and wrenching on his FJ62 Land Cruiser. He’s the DIY editor at Popular Mechanics and also the founder of the home improvement site, Charles & Hudson, the Webby-nominated family site, Built by Kids, and Tool Crave. When not working, you’ll find him on his board or bike enjoying the LA weather with his family and friends. Follow him on Instagram and Twitter.
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