Subscribe to Father Son DIY Garage on YouTube
Father and son DIY garage have taken on a new project, utilizing a load of pallets to create a rustic coffee table. The project kick-off involved breaking down the pallets, removing the nails, and using a chop saw to cut off the split ends. The pieces were then passed through a jig on the table saw to create straight edges.
After a light planing, the pieces were laid out in a herringbone pattern on a three-quarter inch plywood base. The team glued the pieces and tacked them on with a finish nailer, repeating the pattern until the entire base was covered. After trimming and sanding, they applied a clear epoxy finish, which brought out the colors and texture of the wood. The base was made from rectangular tubing, welded together, and painted with black gloss paint. The table was attached to the base using threaded inserts and decorative lag bolts, and metal strapping was used for the sides. The project cost a total of $137, making it an affordable and stylish addition to any home.
Key Takeaways
- The project involved breaking down pallets, planing the pieces, and laying them out in a herringbone pattern on a plywood base.
- A clear epoxy finish was applied to bring out the colors and texture of the wood.
- The base was made from rectangular tubing, welded together, and painted with black gloss paint, and the project cost a total of $137.
Project Kick-Off
The Father Son DIY Garage team started their project by breaking down a load of pallets. They used a sawza to quickly remove the nails and chop saw to cut off the split ends. After that, they used a jig to cut a straight edge on each piece and then used that straight edge piece to cut a straight edge on the other side. They then did a light planing on each piece to achieve a rustic look.
Next, they grabbed a piece of three-quarter-inch plywood and cut it to three feet long. They then laid out all their dimensions and started gluing up pieces in a herringbone pattern. They repeated the same process and pattern until all sides were covered. Once one side was done, they flipped it over and started the pattern over again. They trimmed off the excess with a finished blade on the circular saw with the track set up so it was nice and straight.
After that, they sanded it with the orbital sander just a light sanding to maintain the texture and colors. They then applied a clear epoxy called glaze coat to give the table a nice shine and a coat to protect it.
For the base, they used rectangular tubing and made three lines at 18 inches each. They then laid out a 110-degree angle at every point and cut out the X area with an angle grinder. They sanded the edges for a nice fit up and bent the pieces up. They then clamped them together and welded them up, putting a full weld on every seam. They welded a piece of flat bar to the top, which attached to the table.
They used metal strapping along the edges and attached the legs to the bottom, drilling through that metal. They used threaded inserts to attach the legs to the table. They then put decorative lag bolts periodically around the table and added strapping on the sides. The total cost of the project was $137.
Breaking Down the Pallets
The team at Father Son DIY Garage started their project by breaking down the pallets. They removed any junk and kept the best pieces after removing all the nails. They used a chop saw to cut all the split ends off and then moved onto the table saw. They used a jig to cut a straight edge on each piece and then used that straight edge piece to cut a straight edge on the other side. After that, they did a light planing on each piece to give it a rustic look.
They then grabbed a piece of three-quarter-inch plywood and cut it at three feet long. The project was going to be a coffee table, so they nailed all of their pallet wood pieces to this plywood to hold it together nice and strong. The team laid out all of their dimensions and created a herringbone pattern. They used different size pieces, three-inch pieces, and two-inch pieces, and switched those with every single run.
Once one side was done, they flipped it over and started the pattern over again. They checked in with their speed square to make sure everything was nice and put together. They trimmed off those sides with a finished blade on the circular saw with the track set up so it was nice and straight. Then they started doing the pattern off the side. They trimmed off all that excess once that was all done and sanded it with the orbital sander just a light sanding.
The team wanted to give the table a nice shine and a nice coat to protect it. They used a product called glaze coat, which is pretty much a clear epoxy. They poured some epoxy resin on the tabletop and used a propane torch to remove any small bubbles. They applied a second coat of epoxy for the table and put their final coat on.
For the base, they decided to make it out of rectangular tubing. They made three lines at 18 inches each and laid out a 110-degree angle at every point. They used an angle grinder with a cutting wheel to cut out the parts they didn’t need and then sanded the edges so they weren’t sharp. They clamped them together so they were the same exact spot and welded them up. They put a full weld on every single seam and then went back and sanded it nice and flat.
With the rectangular tubing all done, they welded a piece of flat bar to the top, which was going to attach to the table. They used metal strapping along the edges and attached the legs to the bottom. They used threaded inserts to secure the legs to the table. They put decorative lag bolts periodically around the table and added strapping on the sides.
The total cost for this project was $137, making it a budget-friendly project that turned out looking great.
Cutting and Planing
The first step in building the coffee table involved breaking down the pallets and selecting the best pieces. The team used a sawzall to remove the nails and a chop saw to cut off any split ends. Then, they used a table saw with a jig to create a straight edge on each piece. Afterward, they did a light planing on each piece to achieve a rustic look.
The team used a piece of three-quarter-inch plywood for the base of the table, which they cut to three feet long. They then laid out the dimensions for the herringbone pattern they would create with the pallet wood pieces. They glued and tacked the pieces onto the plywood to hold them together. The team repeated the pattern on each side of the table, using both three-inch and two-inch pieces of pallet wood.
Once the pattern was complete, they trimmed off the excess wood with a circular saw and sanded it lightly with an orbital sander to preserve the texture. They then applied a clear epoxy resin called glaze coat to the table top, which enhanced the colors and provided a protective finish.
For the base of the table, the team used rectangular tubing, which they cut and welded together. They attached the legs to the base using threaded inserts and decorative lag bolts. Finally, they added metal strapping along the edges of the table and painted it black.
The total cost of the project was $137, with the pallet wood and plywood being free. The metal for the base and trim cost about $30, while the epoxy resin and paint cost about $50. The hardware cost $10, and the paint set was $7. Overall, the team was pleased with the outcome of the project and encouraged others to try building with pallets.
Preparing the Plywood
The first step in building the coffee table was to break down the pallets and select the best pieces. After removing all the nails, the team used a chop saw to cut all the split ends off and then moved on to the table saw. They used a jig to cut a straight edge on each piece and then used that straight edge piece to cut a straight edge on the other side. The pieces were then lightly planed to achieve a rustic look.
Next, a piece of three-quarter-inch plywood was cut to three feet long and laid out on a work surface. The team then began nailing the pallet wood pieces to the plywood in a herringbone pattern. They glued up the pieces and tacked them on with a finish nailer, repeating the pattern until all sides were covered. Once the pattern was complete, the team trimmed off the excess wood with a finished blade on a circular saw with a track setup.
After sanding the tabletop with an orbital sander, the team applied a clear epoxy product called glaze coat to give it a nice shine and a protective coat. They poured the epoxy resin on the tabletop and removed small bubbles with a propane torch. The team then mixed up a second coat of epoxy and applied it to the table.
For the base, rectangular tubing was used. The team made three lines at 18 inches each and laid out a 110-degree angle at every point. They then used an angle grinder with a cutting wheel to cut out the X-marked areas. The pieces were sanded and bent, clamped together, and welded with a full weld on every seam. A piece of flat bar was welded to the top to attach to the table.
After painting the metal strapping with black gloss paint, the team drilled holes in the legs and attached them to the bottom of the table using threaded inserts. They repeated the process on the other side and attached decorative lag bolts around the table. The final cost of the project was $137.
Creating the Herringbone Pattern
To create the herringbone pattern for their coffee table, the team at Father Son DIY Garage used a combination of pallet wood pieces and a three-quarter inch plywood base. They first broke down the pallets and removed any unwanted nails and debris. Then, they used a sawza to cut the pieces to size and a chop saw to cut off any split ends.
Next, they used a jig to cut a straight edge on each piece and then used that straight edge piece to cut a straight edge on the other side. They planed the pieces lightly to maintain their texture and color before laying them out in the desired herringbone pattern on the plywood base.
To hold the pieces together, they glued and tacked them on with a finish nailer. They repeated the pattern on each side and trimmed off excess material with a finished blade on a circular saw. They used two different sizes of pieces, three-inch and two-inch, switching them with every single run.
Once the pattern was complete, they sanded the table with an orbital sander, careful not to remove too much of the texture. They then applied a clear epoxy resin called glaze coat to the top of the table to give it a nice shine and protect it.
For the base, they used rectangular tubing and cut it to size, bending and welding the pieces together to form the legs. They attached the legs to the bottom of the table using threaded inserts and decorative lag bolts. They finished off the sides with metal strapping and a coat of black gloss paint.
Overall, the project cost around $137, with the majority of the cost going towards the epoxy and paint. The team was pleased with the final result and recommends using pallet wood for budget-friendly DIY projects.
Trimming and Sanding
After breaking down the pallets, the pieces were trimmed to remove any split ends using a chop saw. Then, the pieces were sent through a table saw with a jig to create straight edges. The team used a light planing technique to maintain the rustic look of the wood.
Once the pieces were ready, they were arranged in a herringbone pattern on a three-foot-long plywood base. The team glued and tacked the pieces onto the plywood using a finish nailer. They repeated the pattern on all sides until the entire table was covered.
After the pieces were attached, the team trimmed off the excess using a finished blade on a circular saw with a track setup. They then sanded the table with an orbital sander to maintain the texture of the wood.
To protect the table and give it a nice shine, the team used a clear epoxy product called Glaze Coat. They applied a thin coat as a sealer, followed by a flood coat for the final top coat. The team used a propane torch to remove small bubbles in the epoxy.
For the base of the table, the team used rectangular tubing and welded it together. They then attached the legs to the bottom of the table using threaded inserts and decorative lag bolts. Metal strapping was added along the edges for a finished look.
The total cost of the project was $137, with most of the materials being free or already on hand in the garage.
Applying the Epoxy Finish
After completing the herringbone pattern on the coffee table, the next step was to apply the epoxy finish. The father-son duo decided to use a product called Glaze Coat, which is a clear epoxy that provides a protective layer and a nice shine.
To begin the process, they taped around the edges of the table to prevent too much spillage. Then, they poured a thin coat of epoxy as a sealer and let it dry. After that, they applied the final flood coat of epoxy.
While laying out the epoxy, there were some small bubbles, so they used a propane torch to remove them. After the initial coat, they noticed that the epoxy soaked into some areas, such as the nail holes and cracks, so they knew they would need a second coat.
The epoxy really made the colors of the wood pop, and the father-son team was pleased with the result. They mixed up a second coat of epoxy and applied it to the table.
Once the epoxy finish was complete, they moved on to making the base of the coffee table. They used rectangular tubing and welded it together, then attached it to the table. Finally, they added metal strapping along the edges and decorative lag bolts periodically around the table.
The total cost of the project was $137, which included the pallet wood, scrap plywood, metal for the base and trim, epoxy, hardware, and paint. The father-son team was satisfied with the budget-friendly project and happy with the way it turned out.
Building the Table Base
The team at Father Son DIY Garage started building the table base by breaking down pallets and selecting the best pieces. After removing all the nails, they used a chop saw to cut all the split ends off and then used a jig to cut a straight edge on each piece.
To achieve a rustic look, they did a light planing on each piece and laid out all of their dimensions for a herringbone pattern. They glued up pieces and tacked them on with a finish nailer, repeating the same process for each side.
Once the tabletop was complete, they sanded it with an orbital sander and applied a clear epoxy called Glaze Coat to give it a nice shine and protection.
For the base, they used rectangular tubing and welded a piece of flat bar to the top to attach to the table. They added metal strapping along the edges and decorative lag bolts periodically around the table.
The team used threaded inserts to attach the base to the tabletop and added strapping to the sides for a nice flush fit.
Attaching the Base and Final Touches
After completing the herringbone pattern on the table top, the next step was to attach the base. For the base, rectangular tubing was used, with dimensions of two and a half by inch and a half and one eighth thick. Three lines were made at 18 inches each, and a 110-degree angle was laid out at every point. The X off area was cut out using an angle grinder with a cutting wheel. The edges were then sanded to get a nice fit up, and the pieces were bent and clamped together before being welded up. A full weld was put on every single seam, and the edges were sanded flat.
A piece of flat bar was then welded to the top of the rectangular tubing to attach to the table. The epoxy resin was poured on the table top, with masking tape around the edges to prevent too much spillage. After the initial coat, a second coat of epoxy was mixed up, and the final coat was put on. The table was then sanded with an orbital sander to give it a light sanding, preserving the texture and colors.
The next step was to make the base for the table. The metal strapping was welded along the edges, and a nice coat of black gloss paint was applied. The legs were attached to the bottom of the base, and the strapping was placed on the sides. Decorative lag bolts were used periodically around the table.
The cost breakdown for the project was as follows: pallet wood was free, a scrap piece of plywood was used for the undercoat, and all the metal for the base and trim cost about $30. The epoxy, epoxy paint, hardware, and paint set cost about $67. The total cost of the project was $137.
Overall, the father-son duo at the DIY garage successfully transformed a load of pallets into a rustic coffee table with a clear epoxy finish and a sturdy metal base.
Cost Breakdown
The coffee table project featured in the video was created using a combination of free pallet wood, scrap plywood, and metal. The total cost came out to be $137.
The pallet wood was free, and a scrap piece of plywood was used as the undercoat, which was also free. The metal used for the base and trim was around $30, while the epoxy and paint came out to be around $50. The hardware, including the new square head lag bolts, was around $10, and the paint set cost $7.
Overall, the project was completed on a budget and turned out to be a great addition to the father-son DIY garage’s collection of projects.