How fun are all the pallet ideas you can find all over Pinterest? This is where the inspiration for this DIY Pallet Bar Cart project came from, not to mention all the FREE stacks of pallets I keep seeing everywhere. The five pallets I used for this cool, one of a kind Bar Cart were rescued from the front of our local community post office. Here is a great pin to help you find free pallets in your area.
- 2 equal size/shape pallets in great condition
- 3 pallets for parts
- 4 heavy duty casters
- disposable nitrile gloves
- paint towel/rags
- 2 cans “antique white” Varathan wood stain
- 200 screws or less
- measuring tape
- “L” shaped ruler
- belt sander with cloth dust bag
- circular saw
- set of sawhorses
- 16 bolts
Place the inseams of the two equal size/shape pallets across from each other. The complete distance including a space should be 16 inches apart.
The three extra pallets are needed for the wood boards. Use your measuring tape, “L” shaped ruler and pencil to mark and measure 16 inches across. Cut each board on the lines with the circular saw. Depending on the width of the boards on each of the ‘parts pallets’ you will need to cut approximately 32 – 16 inch boards to create a top shelf, middle shelf and bottom shelf.
Before you begin filling in each of the shelves with boards you will need to secure the entire structure by screwing boards on the ends of all three levels (a total of 6 boards at this point). This will ensure that the cart is exactly 16 inches apart from top to bottom. Next you will place all your pre-cut boards side by side in the remaining spaces. Do not start screwing them in place until you have them the way you want. Take the time to screw each board to the main structure in a way that looks pretty because you will see all the screw tops in the finished cart. Also, take the time to put some screws in the front face and back face of the initial main pallets. This will make sure you have a sturdy cart that won’t fall apart on you over time and can handle all the items you will place in it and on it.
Yes, I actually took the time to sand every edge of all 32 cut boards. This step was time consuming and is totally up to you if you choose to do the same. Pallets are not perfect by design and you may like the rough texture all over the entire cart. My cart is in my dining room, so I wanted the surfaces that are going to be touched the most to be as smooth as possible.
In my Tools list above you will see that it says you will need a set of sawhorses. As you can see from the picture I do not own a sawhorse, so my father in-law and my husband created this make shift platform so we could cut all the boards correctly.
A bar cart isn’t a bar cart without wheels. This pallet bar cart is very heavy and in need of four heavy duty casters. You can order these online or pick them up at any hardware store.
Before you secure each of the wheels to the corner bottom posts make sure you pre-drill all the holes, then secure each caster with four bolts. This will make your bar cart extra functional because you’ll be able to wheel it around your home or outdoor space with ease.
A side view of the assembled Pallet Bar Cart on casters.
Here are the items you will need to create a beautiful white wash finish all over your bar cart. Disposable Nitrile gloves to protect your hands from the stain. A package of paint towels to easily apply the stain all over the cart. Last, 2 cans of “antique white” Varathan wood stain. I love the finished look of white wash on my pallet bar cart but your style may be different, so here are few other options. You could give it a traditional look by using a brown stain or you could make the bar cart pop by using your favorite color stain or skip the stain and use paint.
This photo shows the front view of the completed Pallet Bar Cart. The back side of the cart looks identical which makes it perfect to set up for a party in the middle of a room or to push it up against the wall. As you can see from the photo I left both the pallets fully in tact. I like that I can place anything I want onto the shelves and it is somewhat hidden away. If you would like to have it more open then you could remove some of the center boards on the front and leave the back side in tact for better support.
Tips ~ Make sure to complete this entire cart in an outdoor space because the saw dust will be everywhere. You’ll also need a well ventilated area because the stain has a strong odor (goes away within a few days). Pre-stain or paint each of the 32 boards and the two main pallets. I did not do this, which made it more time consuming and difficult to stain every inch of the cart when it was fully assembled. I’m proud to say that I completed this entire project in one day…..with the help of my wonderful father in-law and my loving husband!
Hope you find this post pinteresting enough to make your very own DIY Pallet Bar Cart with the next pile of pallets that you come across. Be sure to let me know in the comments section below when you do. I can’t wait to hear all about how you added your own personal style to your cart.