How To Break Down a Pallet Safely (DIY)

Introduction

Wood shipping pallets are rectangular platforms that protect and contain heavy items or stacks of items during transport. Some pallets have a second life as free or purchased material for creative DIYers and woodworkers everywhere.

Shipping pallets are made of multiple thin boards nailed together over three or four perpendicular stringer pieces. Most in North America are 48- by 40-inches. Pallets can hardwood or softwood. Hardwood pallets are tougher and harder to break so you'll probably get the best yield of wood from these rather than softwood.

The platform boards are usually 3-1/2-in. wide and vary in thickness from 5/16- to 1/2-inch. Stringer pieces range from 3/4- to 1-1/2-in. thick and average three inches in vertical width, although exact dimensions vary. From each pallet, you can expect to retrieve 10 to 12 boards around 36- to 40-in. long, 3-1/2-in. wide and 1/2-in. thick. You'll also get three or four stinger pieces.

Good shipping pallets are substantial, which is one reason DIYers have long embraced them as a source of free wood. Do a quick Google search for "reclaimed pallet projects" and you'll see dozens of beautiful benches, tables, chairs, shelves, boxes and more, all made of wood reclaimed from pallets. If you're interested in using pallet wood for a project, learning how to break one down safely and efficiently is the first step.

A few words of warning before you start:

Pallet wood is sometimes low quality, and can be infested with bugs, rot, mold and mildew. Pass on pallets with any of these problems.
Pallets aren't usually treated with dangerous chemicals. But they often break during use, leaving sharp slivers of wood that can hurt you. We recommend wearing tough leather gloves when handling pallets.
Almost all pallets come with rusty nails protruding somewhere. Take extra care to avoid cutting yourself on these.
Pallets are too large to fit in the trunks of most cars, so you'll probably need to a pickup truck for transport. Or ask someone to deliver the pallets to your home.

Once you've found enough pallets for your project — local construction companies and hardware stores can be great sources, but be sure to ask permission — gather the proper tools and get started.