Not just a DIY pallet bar - but a portable folding pallet bar.
Everyone should have a DIY pallet bar! At first I was stressing over June’s Power Tool Challenge theme. Summer Fun! Until, I figured out I wanted to make a DIY pallet bar — not just any old pallet bar, but a folding, portable bar-great for a wedding or outdoor event.
See how happy I am that the pallet bar is finished!
Let’s see how it all came together . . .
I forced myself to visit the back of the storage shed to scope out the existing pallets I had in storage. ewwww
You will need 2 pallets for this DIY pallet bar
The pallets were so gross, I immediately cleaned them off with the hose. I was trying to match up the pallets to see if they were similar because I had a special plan. Rarely do I know what I’m going to do going in. There were some changes that took place, but for the most part, this portable pallet bar ended up just as I saw it in my head.
The plan was to cut one of the pallets in half. By using a spare 1x board, I was able to only clamp the wood (guide) in place one time. I put it dead center, and slid the circular saw on the right side, then came back the other way. turn over repeat.
Cut Pallet in Half
When using a circular saw, you need to set the blade depth to prevent kick back. (don’t ask me how I know—it’s a lesson I learned years ago in my 20’s)
After examining all of the boards for nails and or screws, I used the guide to keep the circular saw on track. Then, proceeded cutting the pallet boards. Note the clamps must be on the opposite side of the cutting area.
You can see that I have cut half of the pallet, and am in the process of changing the clamps so I can come back from the other direction. If I were to change the clamps and go in the same direction, the distance between the board and the blade would be much greater, therefore making the halves of the pallet unequal.
As I was coming toward the end, the board and all the scraps fell through. Time to flip it over and do the same on the other side. (not shown)
Add Each Half Pallet to Whole Pallet
You can see how it’s going to come together as I’m doing a dry fit.
This is where the portability of the pallet bar comes in to play. I have this old tackle box full of door hinges I got from a friend years and years ago. They changed out the color of their knobs and hinges and I got all the old ones.
I searched and searched online for a similar bar that folds up and I was unable to find anything. Most pallet bars have this shape, and many are made with pallet boards, but I chose to make mine with 1 whole pallet and 1 pallet cut in half (well, a little smaller than half)
I did the left side first and struggled with it, so I’ll show you the right way to add these hinges. Put all three hinges on the full pallet – folding each hinge back as you attach them. I used a quick clamp to help hold the hinge in place. I drilled pilot holes just to be sure the pallet boards didn’t split. Having two drills going at the same time is very helpful for this stage.
Fold each hinge inward, and prepare to attach the side of the pallet bar.
Pallet Bar Folds!
voila! Oh my gosh! It’s just as I had imagined. Look how perfectly it will fold up! Full disclosure: It is very heavy for one old gal to carry by herself.
This is the third pallet shown at the top of this post. Clearly I had used this pallet for painting in the past. I used my Duckbill Deck Wrecker to dismantle the pallet quickly and easily. I then de-nailed all the pallet boards. The plan was to use the boards to make the bar top.
See more Pallet Projects and tips for dismantling pallets by clicking here.
While I’m talking about the Duckbill Deck Wrecker that easily takes pallets apart, I want to make sure you know the best way to do so without splitting your boards. When you position your deck wrecker up against the brace board (on the left) the likelihood of your pallet board splitting is much less than if you center your duckbill deck wrecker over the brace board (on the right)
Yeah, that was a wasted hour. I’m not liking how the portable bar top is looking. But, in this image you get a sneak peek at the adjustable shelving that will be included with this folding pallet bar.
Pallet Bar Top
Plan B!
Years ago I got a ginormous hutch from my cousin. I cut it in half. I used Ā½ of it to hold my sliding compound miter saw. (seen below) The other half of the hutch became a craft table. This long piece leaning against doors was the top to that monster. I’ve never known what to do with it.
I drug it out and placed it on top of the pallet bar to see if it was going to work.
This is part of said hutch I got from my cousin. (home for my large miter saw) That jaw stand really comes in handy for large jobs like this. I cut half of the top, then flipped it over to do the other half. You could use a jig saw or a circular saw to get the same result.
Flipping the table top over, and being VERY careful to avoid any screws and/or nails I finished cutting the end off of the large plywood hutch top.
To make the cut off end match the other end, I used a scrap 1x that I found.
I cut more fence boards to allow for adjustable shelves in the portable diy pallet bar. At this point I’m really happy with how well it’s coming together, but I wanted to make sure that the top rested on the pallet bar securely.
Add Cleats to Bar Top
Using some of the scrap boards from the pallet I dismantled, and another piece of hardwood I made inserts to keep the pallet bar top from shifting once it is placed on the pallet bar. I attached the pieces with my nail gun, checked to make sure they fit okay, then I secured them with some wood screws.
These are the 3 places where the inserts will rest to keep the pallet bar from shifting once it’s in place. They fit very snug.
You’ll see in the video that they need to fit perfectly in order to secure the bar to the top properly.
If you look closely, you can see the insert here in the middle front of the pallet bar.
The portable bar is easy to move on my small furniture dollies. These things are a lifesaver.
Easy Stool for Pallet Bar
I got busy making a diy bar stool out of weathered 2x4’s and some leftover 2x2’s from my porch swing pergola. It’s a really simple build. I used my Kreg Multi-Mark tool to get all the bottom braces placed uniformly.
I painted all the diy portable bar components with my Homeright Finish Max.
Stain & Protect Bar Top
In order to give the bar top a fresh new look, I used Minwax Gel Stain . The color was Hickory.
The bar top is NOT weatherproof, but I did want to make it water resistant because after all, it’s a bar! I attempted to use my favorite Minwax polycrylic for durability—BUT because the gel stain had such a shiny surface, the polycrylic just sat on top of the wood stain.
Luckily, it’s water based, so I was able to wipe it off with a damp rag.
When all else fails, read directions gail! The gel stain recommends Fast Drying Polyurethane. I sanded the top a little with some brown craft paper, wiped it down, then used a cheap chip brush to apply the polyurethane. I did two coats following the directions in between coats.
Are you ready for the reveal? Or have you already scrolled down to see the “after”?
Don’t you want to make your own foldable and portable diy pallet bar? Everything but the top could stay outside in the weather.
Folding Pallet Bar
Wouldn’t it be perfect for an outdoor wedding, or your next bbq?
I LOVE Amazon Prime. I ordered these rope lights with same day delivery. To get it I had to buy at least $35, no problem for me. I added on some printer ink so I could get them right away.
Here is the portable folding pallet bar all dressed up for a party!
A view of the shelving area of the pallet bar—lots of storage area, completely adjustable to the owners liking.
One more option! The shelves can be placed on the top of the pallet bar for a more rustic and weather proof option.
This bar is so versatile—think weddings, reunions, birthday parties, any outdoor event—even tailgating. Ohh, and move it to the FRONT yard for the kiddos to sell lemonade.
The pallet bar easily folds away for storage, taking up very little room in your garage. Additionally, it’s very transportable in your SUV or pickup truck
I hope I have inspired you to make your own portable pallet bar, it’s so easy to make, put up AND store!
Now, it’s time to check out all the Summer Fun projects from my friends.
My Repurposed Life Portable Folding DIY Pallet Bar
Create and Babble Limbo Game Station
My Love 2 Create Ring Toss Game
The Kim Six Fix Cornhole Game From Cabinet Doors
H2OBungalow DIY Hook and Ring Game Tutorial
Gail Wilson is the author and mastermind behind My Repurposed Life. She is obsessed with finding potential in unexpected places and believes that with a little hard work and imagination, any old thing can be made useful again, including herself!
Gail reinvented herself during a midlife crisis and has found purpose again. She hopes you will find new ideas for old things and pick up a few tools along the way.
Aisha Young
I'm recreating this for my wedding, but having a heck of a time getting the side pallets (the one cut in half) to hang straight. The pallets were in such good condition too. Did you struggle with the kind of thing at all? Trying to determine how much perfection I really need.
Gail Wilson
Hi Aisha!
Are you connecting the CUT side or the original side? I would recommend using the original portion of the HALF pallet.
Are you working on a flat surface? Hinges are funny beasts, I struggle with them too. I'm here to help in any way I can. You can email me pics if you'd like. Or reach out on facebook (messenger)
gail
Carol
I can't believe the things you come up with to epicycle "stufff".
Truly amazing project you have there. Not only functional but looks great too!
Keeping those pallets out of landfills ~ Genius!
Gail Wilson
Carol,
Thanks so much for checking out my folding pallet bar. It was fun, and much easier than it looks. The top was a little challenging, but I'm always trying to "use what I have".
gail
Nancy
Hi. Love this, wanting to have a table for a grooms cake when you use the shelves as table top, was it secured down or just laid on top ?
Gail Wilson
Nancy,
The top I used was very heavy. I made cleats on the underside of the top, so that the top could not shift. It rests in between wood to keep it secure.
I hope that helps.
gail
RHONDA R SPECK
I can't find anywhere that it gives the finished dimensions of the bar. I need to know because I'm limited on space. Love this bar and hope I can make it, with some help.
Gail Wilson
Rhonda,
I can't really give you dimensions because I have no idea how large a pallet you will be using for your project. Pallets come in many different sizes. You will need to search for a pallet that fits your needs.
gail
RHONDA R SPECK
What are the dimensions of the one you made?
Gail Wilson
I'm sorry, I don't know. I sold it.
They were 2 pallets pretty equal in size. One full one, and one cut in half.
gail
sylvia white
What size pallets did you use? So excited to get started!!
Gail Wilson
Sylvia,
They were just regular sized pallets. It's best if you can find two that are similar in size. I'm so happy I inspired you to make your own project! Keep me posted on how it goes.
gail
Frank
this is awesome! could you share the measurements on the stools?
Gail Wilson
I totally meant to measure the stool today, but I forgot. It's crazy around here, I'll try to get to it in the next few days.
gail
Robin
Hi Gail,
I love the pallet bar. Going to try to make one for a shower gift. What kind of white paint did you use? Paint or stain? It looks like the grain is still visible, which I love. Thanks so much for the idea!!
Gail Wilson
I used a whitewash effect on the pallet bar.
I thinned some regular latex wall paint with water and applied it with a cheap chip brush. š
Hope that helps, good luck with your project!
gail
Patricia Garza
How do you keep the bar from falling forward?
Gail Wilson
Hi Patricia,
The bar is weighted enough that it firmly plants itself. The sides and the top offer enough stabilization that it isn't a problem. I hope that helps.
gail
Diena Cameron
Wow Gail, that bar is perfect and i am about to embark on a similar project. I'm so glad you did it first so now I know what to do .) I love the size, the ease of making, the extra shelves, fact the top is different than sides using stain and poly, the weathered finish on the sides, the portability of it and all in all......the price (at least for me .) Did you put any paint or poly on the sides ? I didn't see you add anything to them, i love them. Your pictures and videos tutorials are wonderful and so detailed that even school children could follow them. I was wondering, is it possible to pull the sides in flush with the front and add the hinges to the outside ?? I was thinking of doing black iron hinges and a black top but i have not had much experience using hinges so not sure about configuration of the sides, if it would work right and still fold up, i would think it would make the "inside" where shelves would be, a bit smaller but that would be ok with me if you think it would work. Sorry for the letter, i just love "ALL" your projects ! PURE TALENT .)
Gail Wilson
Thanks so much for your enthusiastic comment Diena! It makes me smile!
I hope this explanation will make sense.
I cut the pallet NEARLY in half. If you were to cut the pallet exactly in half, attach the hinges on the front, they may rest NEXT to the side of the front pallet, where mine rest BEHIND the front pallet. But as I type this, and see it in my head, I think the hinges would not allow the sides to swing all the way to the side, but only outward to make one very large front.
I honestly can't wrap my brain around making it fold and open with hinges being seen.
let me know if you make this project.
gail
Diena Cameron
Haha, I'.m. glad I'm not the only one stumped about this. What about piano hinges, do they work both ways ?? I have seen hinges that work both ways on one of my diy shows, i think they were making a privacy screen, you know the kind with three panels that you can cover with batting and material, usually in bedrooms ? I think they used those kind of hinges so they could use both sides of the screen. Well I'm on the hunt for hinges and it will a couple weeks but i will try and post your a pick ! .) Thanks for your help, let me know if you figure it out, ok ?
Gail Wilson
Piano hinges won't work.
I have small bi-folding hinges on my fireplace screen made out of small shutters. They are called "Double Acting Folding Screen Single Hinge". The ones I used would be way too small for what you want.
If you have to use non-decorative hinges, why not just do them the way I did? š
gail
Diena Cameron
I thought maybe it would be cute if they were on the front and painted black or purchased black like wrought iron ones and then stain the top black and seal if with a Marine grade poly. We don't have a covered deck and my poor hubby is getting really tired of hauling my white wicker chairs to the basement everytime it rains, lol
Being here on the Oregon Coast where you never know if it's going to rain or not, I broke down this summer and bought furniture covers for all my chairs and I bought an offset umbrella and then a smaller one for the bistro table and 2 chairs so if it does sprinkle it won't be too bad on the furniture. Winter though is a different story. Wish I had a Wisteria covered Pergola .) #dreamer Have a wonderful weekend Gail !
Diena Cameron
Thanks for the info Gail.
Bliss
Just stopping in for some lemonade and to pin the pallet bar.
Serena @ Thrift Diving
I absolutely love this, Gail!! Don't you love when an idea comes to fruition?! It's perfect and I could see this being something many people do for their own backyards! Well done, girlfriend! Pinning! š
Missy Wilson
OMG.....You are not intimidated by those power tools at all! That is one great BBQ bar!
Toni
OMG - You stood in line many time when creativity was given out! I love seeing the amazing things you make! If I lived near you I'd love to take classes! Do you teach>
Thanks for all the great eye candy stuff!
Gail Wilson
Toni,
Thank you so very much for that sweet comment. I don't teach, I just share all my repurposed furniture ideas right here on the blog. It's my way of sharing what I learn with my friends.
gail
Danyle Verzinskie
I love this project. I cant wait to make one for myself! I have seen lots of pallet ideas but this is the first one I liked enough to want to actually make and use. Great IDEA!
Gail Wilson
Thanks so much for stopping by and taking the time to leave a comment Danyle. It's very much appreciated. This is a fun and easy project, you should definitely make one!
gail
Cat
Looks fantastic...perfect for my backyard and kids lemonade stand and my new patio Bar lol I am going to make like 3. What else can I use for a top. Something that is waterproof?
Gail Wilson
What else for a top? That's a great question Cat. You could use more pallet boards, they hold up well in the weather? Or, wider fence boards? Those are both treated, so I wouldn't let food come in contact with them.
I would LOVE to see what you come up with!
gail
Mindi
Gail this is the perfect outdoor bar! I am LOVING how you made it to fold up, and the shelves, and the cute bar stool! It is so awesome in everyway! You shared so many great tips in this post too, for sure pinned!
Gail Wilson
Thanks so much Mindi! Wouldn't this portable pallet bar be perfect for lemonade sales too? You should make one for your kiddos!
gail
Paula
Amazing! I love this idea! Making it fold is great for those who don't have a space to leave a bar out year round. I think our patio at the lake is in need on one of these!
Gail Wilson
Paula,
This pallet bar was such a fun and easy project. Plus it got two pallets out of my storage area. š
Thanks for stopping by,
gail
Karen @ The DIY Bungalow
That is so great! I love the repurposing, of course, but all that storage!! You are so creative!
Gail Wilson
Karen,
I was really excited about this folding pallet bar project. I wanted to share it as soon as I got it done. Hoping you get to join in next month with the power tool gals.
gail
girlfromwva
WOW! such an awesome finished bar!!! might have to figure out if i can actually put one together!
Gail Wilson
Sure you can put together a fold up pallet bar Nova! Maybe you can find a good deal on some hinges at the ReStore or thrift shop.
The top might be more difficult to find. I was really lucky - I've been wanting to use that big piece for a couple of years now. Great project, plus I got rid of a few pallets and a piece of wood. š
be sure to let me know if you make one.
gail
Sandy
This is awesome! And the parts are so readily available. Thanks, Gail, for another inspiration.
Gail Wilson
Thank you Sandy. I appreciate your comment.
gail
Gail Gibson
Hi Gail - another great idea. Your projects are wonderful. So this is HI! from another "ol gal" Gail.
Gail Wilson
Hi there Gail! It's from to hear from another ol gal Gail! Thanks for saying hi!
gail
Wendi@H2OBungalow
Shut the door girlfriend, this project rocks! Will you bring it over so we can have a party? It will go great with the other games from the team! LOVE! Pinned and shared..of course š
Gail Wilson
I can't believe I was the only one in the challenge that didn't make a game Wendi! I guess my summer fun ideas are a little different than the rest of the gals. š
Thanks for pinning!
gail
Carol S
Oh yeah! Pinned this one. Great idea and execution! Really cool!
Gail Wilson
Carol,
I looked and looked online and couldn't find another folding pallet bar anywhere. It's so rare to think of something "new" these days.
Thanks so much for pinning!
gail
Jeanie
Another awesome project Gail. I love it, especially with the lights - perfect for a wedding! Pinning!
Gail Wilson
You're so right Jeanie, this portable pallet bar is perfect for a wedding, and so much more. Even tailgating! Can you imagine, I'd be the envy of the parking lot!
thanks for pinning!
gail