DIY Pallet Armchair | Step-by-Step Construction Guide 2026

Building a pallet armchair isn't complicated—just get a few good reclaimed pallets and you're ready to go. This DIY pallet armchair is truly rustic: built from natural, weathered pallets with stamps and markings still visible, it measures just under a meter wide (cozy for two), and comfort comes entirely from two cushions. Yet the final look is charming, perfect for a garden corner near a cast-iron fountain, a stone sink, a rosemary bush, or an oriental-style lamp.

What You Need to Build a DIY Pallet Armchair

Materials include 3 euro pallets for the base, seat, and armrests (standard size 800x1200x150 mm). You'll also need 14 reclaimed planks from other pallets (various sizes, 20 mm thick), 8 joists 185x50 mm (75 mm thick), 2 swivel casters and 2 swivel casters with brakes (70 mm diameter), 8 self-tapping flat-head cross screws M4x40 mm for casters, 8 washers, 6 self-tapping flat-head cross screws M4x30 mm for pallet fixing, 7 self-tapping flat-head cross screws M4x40 mm for armrests, wood nails, and walnut-colored outdoor protective stain. For tools, you'll need a miter saw, handsaw, drill, screwdriver, orbital sander with abrasive discs, and a brush for the stain.

Step-by-Step Construction

1. Measure and Cut the Pieces

Start by measuring the pallets and cutting the planks and joists to size. Use a miter saw for clean cuts. Sand all pieces with an orbital sander to remove splinters. Apply the first coat of protective stain and let it dry for 48 hours before proceeding. While waiting, you can browse our home improvement collection for additional tools or finishing supplies.

2. Build the Base and Seat

Assemble the base using two euro pallets stacked and screwed together. Attach the four casters (two with brakes) to the bottom using M4x40 mm screws and washers. For the seat, place the third pallet on top and secure it with M4x30 mm screws. This creates a sturdy foundation. If you're working outdoors, consider our garden supplies for protective covers or storage solutions.

3. Create the Backrest

The backrest is made from reclaimed planks attached to joists. It needs to lean slightly backward for comfort. Cut a recess into the seat pallet to fit the backrest, then reinforce it with additional joists and planks for a continuous line. Secure everything with M4x40 mm screws. For a cozy outdoor setup, pair it with items from our outdoor patio furniture collection.

4. Attach the Armrests

Cut two armrests from the remaining pallet wood. Fix them to the sides using M4x40 mm screws, and dowel them to the backrest board for extra stability. Sand any rough edges and apply the second coat of stain. Let it cure for another 48 hours. To complete your outdoor living space, check out our outdoor decor for accent pieces.

5. Add Cushions and Finishing Touches

Place two large cushions on the seat and backrest for comfort. The armchair is now ready for use. For evening gatherings, add outdoor lighting from our collection to create a warm ambiance. You might also want to protect your cushions with storage solutions from our storage benches range.

Tips for a Professional Finish

• Use a level to ensure the base is even before attaching casters.
• Pre-drill holes to prevent wood splitting.
• Apply stain in a well-ventilated area and allow full drying time between coats.
• Consider adding a waterproof cover or storing cushions when not in use. Our sheds collection offers great options for garden storage.

Frequently Asked Questions (FAQ)

1. How long does it take to build a pallet armchair?

With all materials ready, construction takes about 4-6 hours, plus drying time for the stain (48 hours between coats). Plan for a weekend project.

2. Can I use this armchair indoors?

Yes, but ensure the stain is low-VOC and suitable for indoor use. For indoor settings, you might prefer our sofas collection for a more upholstered option.

3. What if I don't have reclaimed pallets?

You can buy new pallets or use dimensional lumber. Alternatively, explore our home improvement section for ready-made furniture kits.

4. How do I make the armchair more comfortable?

Add thick foam cushions with removable covers. For extra coziness, consider outdoor rugs and curtains to define the space.

5. Can I customize the size?

Absolutely! Adjust the number of pallets or planks to create a loveseat or single chair. For larger projects, our pergolas and gazebos can help create a complete outdoor room.

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