Pallets are an excellent resource for creating a variety of practical, budget-friendly items for your home and garden. One of the top beginner-friendly wood pallet DIY projects is crafting a custom workbench for your garage. Let’s explore how to do this.
I’m Onions Australia’s expert carpenter and remodeler. Over the years, I’ve had several workbenches, so I have a solid understanding of the essential features. Although I now have an extensive toolkit, I remember when I didn’t. Therefore, I’ll keep this simple, using minimal tools. If you’ve done even a bit of home improvement, you likely already own most, if not all, of them.
For the basic DIY pallet workbench, you’ll need a hammer, a drill/driver, a saw, a tape measure, a straightedge, and a pencil. A circular saw or jigsaw will make things easier, but a hand saw will suffice. A sander would be beneficial, but a sheet of sandpaper wrapped around a scrap block of wood will work. Gather some 1-½ inch wood screws (or similar size). Also, check out local spots for free pallets, or repurpose old wood pallets you may already have. For a deluxe version, you’ll need a sheet of 1/2 inch or 3/4 inch plywood or MDF and some heavy-duty casters, like the Ashgoob 3-inch Castor Wheel Set.
Building the custom wood pallet garage workbench
Our custom workbench requires four pallets. Since pallets can be quite worn, choose ones in decent condition when collecting old ones for reuse. They can be repaired, but ideally, it shouldn’t be necessary. If the pallets at one location are in poor shape, look elsewhere; there should be plenty available.
Once you have your pallets, ensure there are no exposed nail heads. If present, hammer them in to avoid injury while working. Set aside the pallet with the best top surface for your benchtop.
To create the two sides, remove all the boards on one side of the pallet between the end and middle support blocks. Measure the thickness of your benchtop pallet and mark that distance on the sides opposite the removed boards. Measure from the edge back towards the middle and saw through the remaining boards. You should have an “L” shape. Position the sides vertically with the remaining blocks at the bottom, facing inwards. Place the final pallet between them on top of those blocks, then position your benchtop pallet across the middle blocks. The top should align with the top of the “L.” Secure with three equally spaced screws through the sides into each block of the horizontal pallets. Voila! You have a sturdy workbench for your garage. Sand any rough edges to prevent splinters.
A few extras to make your custom workbench even more useful
Enhance the DIY pallet workbench with a few additions. It offers great strength but isn’t easily movable. Attach heavy-duty casters to each corner to solve this. Opt for those with a built-in foot brake so it remains stationary while working yet can be easily moved from the garage to the yard.
A solid top is preferable to slats, so cut a piece of plywood or MDF to size and secure it with screws at the corners. MDF is typically cheaper and smoother, though not as durable as plywood. Either way, consider the top sacrificial: when worn, simply replace it.
Add tool and accessory pockets to the workbench ends for a final upgrade. Use offcuts or another pallet if needed. Cut pieces to length, then screw the edges together to form an “L.” Decide on the number of dividers, cut and screw them in place, and add ends. Avoid screwing on the front initially, as it complicates attachment to the bench. Attach the back of the “L” to the workbench end, then add the front. Now, you’re ready to tackle unique small wood pallet projects for your home and garden.
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