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How to make DVD shelves from a pallet
In this area of Spain storage is a problem and I needed to create more space. I asked my husband to bring home one of the pallets they would throw away otherwise to build us 2 DVD-shelves.
The pallet wasn’t in the best shape which was good for me. I don’t want to show you how it’s done with a good pallet and then you get a bad one and don’t know what to do…
The 2 shelves I made in different designs and I explain how to do both.
– a pallet,
– a tape measure,
– a claw hammer,
– a hand saw,
– a drill,
– screws and screwdriver,
– wood glue and wooden dowels (for one of them),
– wood filler,
– a putty spatula,
– wood varnish (I used 2 shades: pine and teak)
– white chalk paint for the other shelf,
– paint brushes,
– a clear sealant (I used a spray) for both shelves.
I have used not only 2 different painting techniques, but as well 2 different designs. Both of them will be explained starting with the
First step is to get your pallet and cut the three bottom planks exactly where the first top plank ends widthwise. You can use an electric saw, but I would recommend a hand-held one. It´s easier to control you cut straight and it doesn´t leave “burn marks” as some electric ones might.
Next you need to measure and mark 7 cm (~2.76″) on each of the 3 planks and cut these off.
Now comes the hardest part of it all: get one of the top planks off the pallet. I know there is a special tool for this, but nobody is gonna have it at home… (If you do, skip this part and use it!) Take the hammer and knock on the underside of the plank around all 3 places it is attached to the bottom plank. Do NOT hit too hard or you will split it! Once you got the nails together with the plank far enough out to take the nails out using the claw, lay the pallet back down. Carefully hammer the plank back down and take the nails out.
You might have to do this a few times as not all nails will have come out far enough the first time.
If you should have split the plank, don´t worry. That´s why we have the wood glue and the filler as well.
Next we take out the drill and match the drill bit with our wooden dowels. Drill 2 holes, about half the length of your wooden dowel deep, into each piece of plank still attached to our front and 2 into one side of each piece we cut off. Remember that we have to get to a depth of around 14 cm (~5.51″) with both pieces together. I have laid the pieces on for you to see what it is going to look like after the next steps.
Apply glue to the sides you have drilled and to the dowels. Don´t apply too much or it will come out the sides.
Glue all pieces together and let it dry, best over night. If you have a split plank, glue it together as well.
Lay your loose plank over the middle of your joint pieces to form the bottom of the shelf. Using a small drill bit, drill through the plank and into the pieces, two holes at a time.
Use the same drill bit to open up the top holes a bit wider, so the screws will go in a bit further. To achieve this, just move the drill bit in a circular motion. Screw the plank to the bottom of your shelf.
Now we get to use the wood filler on the “ugly” parts of our shelf. Fill the screw holes and cracks using a spatula. If you should have a piece of wood missing like I had here, just apply some filler with your hand. The aim here is not to replace, but to smoothen it a bit. Let the filler dry according to the instructions and repeat filling the screw holes. Let dry again. You might have to repeat this a few more times…
When you are happy with the filling and it´s all dry, rub the whole shelf down with sandpaper and clean it after. Make sure all the dust is gone before you paint. First paint most of the shelf with the pine to keep some of the original wood colour and give it the first impression of a distressed look. Let the paint dry according to the instructions.
With the teak paint, just lightly feather over the shelf to give it some darker areas in the middle where paint wouldn´t wear off as much.
Once dry, apply the clear sealant.
Now to the
Not many photos here. I put the filling ones I done on the white shelf above…
We start by leaving the first plank on the pallet and taking the second and third off as explained above.
Then we measure from the plank 14 cm (~5.51″) in and cut there.
Now attach one of the loose planks next to the other plank and one to the front in the way explained above.
Fill the screw holes and any “ugly” bits.
Rub down and apply some candle wax to a few places, if you want to give it a distressed look. To do this, just take a candle or tea light and rub it on the wood in the places you want.
Apply at least 2 coats of the white chalk paint, waiting the time indicated between coats.
Rub down again where you applied the wax and apply the clear sealant. Done 🙂
Feel free to share your own version in the comments or simply email them to me: tjalva tjalvasdiy.com
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