Step 1: Collect Your Pallets
The first thing you want to do is find 9 good quality pallets. If you’re lucky enough to work in a warehouse or know someone who does, find out if you can pick up a few. If you don’t know where to get free pallets, try calling your local hardware and lumber stores to find out if they carry them. Used pallets is a good way to recycle but make sure that the pallets are still in good condition. The duration of your couch will depend heavily on the quality of the pallets you use.
Step 2: Measure and Cut Your Pallets
Cut all of your pallets down to about 27.5 inches wide then mix and match the pallets until they are in the position you want. You may want to cut out a few of the 2x4s and rearrange them a bit until you are satisfied. Overall, you should be able to create a perfect “L” at about 78″ x 78″.
Step 3: Sand and Assemble
Set the pallets out where you will want your pallet couch and sand all of the exposed pieces. Attach the back using long screws and then stain or paint the assembled pallet couch.
Step 4: Make Your Cushions
Using the assembled couch as a template, mark and cut out your cushions. If you can find some old crib mattresses, you can cut out the foam and use it for cushions. Cover the foam with fabric.