The Complete Guide to Building Pallet Kitchen Cabinets from Scratch

Giving your kitchen a makeover doesn't have to cost a fortune. With some basic DIY skills and recycled pallet wood, you can build stunning kitchen cabinets on a budget. Read on to learn everything you need for constructing and installing custom pallet wood cabinets that will completely transform your kitchen.

Crafting cabinets from reclaimed pallets is an eco-friendly and inexpensive way to achieve a one-of-a-kind look. With a little bit of elbow grease and creativity, you can upgrade your kitchen with unique, rustic-chic cabinets. Let's dive into all the steps for building and installing pallet wood cabinets from start to finish.

Finding and Selecting Pallets

The first step is sourcing wooden pallets for free or cheap. Check local businesses, stores, and warehouses that receive shipments on pallets. You can also find people giving away pallets on Craigslist and Facebook Marketplace. Avoid spending more than $10-20 per pallet.

Examine each pallet carefully before taking it home. Look for thick, untreated wood with no chemical stains. Softwoods like pine aren't ideal as they tend to be more fragile. Inspect the boards for cracks, rot, or nails sticking out that could cause injuries.

Safety Tips When Taking Pallets Apart

• Wear gloves to avoid splinters
• Use pallet crow bar or pry bar to remove boards without cracking
• Beware of protruding nails and staples

Planning Your Pallet Wood Kitchen Cabinets

The next step is mapping out the design and measurements for your DIY pallet cabinets. Start by looking at your existing kitchen layout. Make note of windows, doors, appliances, and plumbing fixtures you need to work around.

Sketch out different cabinet configurations taking into account where you need base cabinets, wall cabinets, pantries, etc. Incorporate drawers, doors, adjustable shelves, and other storage components that suit your needs. Pull-out spice racks or tray dividers are great pallet wood DIY options.

Finalize your kitchen cabinet plan with exact dimensions. This cut list will be critical when constructing the cabinets from your reclaimed boards. Allow for cabinet sides, tops, bottoms, fronts, backs, and face frames. Account for interior dividers, drawers, and doors - both their dimensions and quantity needed.

Tips for Designing Your Pallet Wood Kitchen

• Maximize corner cabinets and blind corner storage
• Use a mix of open and closed storage
• Include drawers for utensils close to the cooktop
• Don't forget lighting inside and under cabinets

Preparing and Repairing Pallet Boards

With your pallets selected and design ready, it's time to dismantle the pallets. Use a pry bar and hammer to remove nails and separate the boards without cracking them. Wearing gloves helps avoid splinters.

Inspect each recovered board and sort them by length. Set aside badly damaged sections. The longest and widest boards are best for the cabinet sides and face frames. Smaller pieces work for cabinet backs, floors, and shelves.

Now prep the boards by sanding down rough edges and surfaces. Start with coarse 60-80 grit sandpaper to remove big scratches and defects. Then use progressively finer 100, 150 and 220 grits to smooth the wood. Wipe away dust between sanding.

Fill any holes, cracks, or depressions with wood filler and let fully dry overnight. Sand again lightly to blend the repairs flush with the surface. Lastly, apply gel stain and polyurethane sealer for protection and your desired look.

Choose Your Cabinet Style

• Modern: Bold colors, sleek hardware
• Rustic: Natural wood tones, visible grains
• Farmhouse: Light colors, visible distressing
• Industrial: Dark stains, black hardware, pipes

Constructing Pallet Wood Cabinet Boxes

With your prepared boards, you're ready to build the structural boxes that make up the cabinet carcasses. Start by cutting the boards to length with a power miter or circular saw. Follow your cabinet designs for sizing.

Assemble the pieces into frames using pocket holes, rabbet joints, or simple butt joints. Apply copious wood glue before driving screws or nailing for ultra-strong results. Reinforce large cabinets by toenailing into an additional back frame.

Next, cut panels of plywood or pallet boards to size for the cabinet backs. The backs keep the boxes square and rigid once installed. Staple or nail the panels into the back rabbet grooves or across interior frame supports.

Attach cabinet doors and drawers using appropriately sized hinges and slides. Test fit doors and drawers to ensure proper alignment before final attachment. shim hinges that don't hang straight.

Structural Reinforcement Tips

• Anchor wall cabinets into wall studs
• Install corner gussets or blocks
• Bridge cabinets together with clamps until secured to wall

Installing and Finishing Kitchen Cabinets

To install the pallet wood cabinets, start by prepping the work area. Remove existing cabinets if needed and clean the walls and floor thoroughly. Locate studs for anchoring wall cabinets later.

Begin by installing wall cabinets first. Level and attach firmly into studs using at least 3-4 long screws through the cabinet back or side walls. For base cabinets, shim and level before screwing them together and into the wall studs.

With all cabinets hung, take exact countertop measurements. Have your new countertop material cut to size and securely fastened to the cabinet boxes. We recommend consulting an experienced countertop installer.

Finally, add hardware like knobs or pulls to doors and drawers. Do any final sanding and apply a last coat of protective sealer. Then load up your new pallet wood kitchen cabinets! Add racks, trays, and bins to maximize storage.

Finishing Touches

• Install under cabinet lighting
• Add glass panel doors for openness
• Incorporate wood or tile backsplash
• Use crown molding for an upscale look

Building your own kitchen cabinets from recycled pallets offers many benefits compared to buying traditional cabinets:

• Cost savings - Up to 50-75% less than custom cabinetry
• Custom sizing - Built to fit your unique space
• Eco-friendly - Repurposes waste wood
• Rustic aesthetic - Charming, natural appeal
• Unique designs - Completely one-of-a-kind style

With some basic construction skills and elbow grease, you can upgrade to stunning pallet wood kitchen cabinets on a budget. Just follow the steps for sourcing quality pallets, planning an efficient layout, prepping and repairing boards, constructing sturdy cabinet boxes, and installing your custom DIY cabinets. Add your own personalized hardware, finishes and touches. Before you know it, you'll have a spectacular new kitchen to enjoy for years to come!