DIY Wood Pallet Floating Bar

We moved into our current house just over a year and a half ago. Since then, one area of our home has felt incomplete. Until now.

Just off of the kitchen in our home we have an area that I refer to as ‘the kitchenette’. Outside of an occasional homework assignment or family gathering requiring table space for food trays our kitchenette is rarely used.

DIY Wood Pallet Floating Bar

Last November my Aunt brought over a page torn out of a Pier 1 Catalog. As she pointed to the kitchenette she handed me the ruffled edge page and said, “I found the answer for this area and here is your inspiration”.

SHE WAS RIGHT! And my husband agreed.

After all, there was already a Kegerator in that space and we had discussed the possibility of adding a ‘bar room’ in this home similar to what we had in our last house.

This was the answer! At least the idea was the answer. My husband and I agreed on a Contemporary yet Industrial look. We also agreed that we wanted a wood pallet bar top.

After researching the height of barstools and considering the height of the kegerator we decided our bar would be 40 inches tall. To decide on the depth of the bar I measured the width of the pallet slats.

The wider pallet slats were 5.5 inches and the smaller slats were 3.5 inches. Two of each would make our bar an even 18 inches deep. Perfect. My husband calculated the length of the wall and concluded that the length of our bar should be 72 inches.

We purchased particle board to serve as the support for our bar; 72 inches long by 16 inches wide which would leave a two inch pallet overhang to ‘hide’ the particle board foundation. And then we got to work!

DIY Wood Pallet Floating Bar

(1) Use a Circular Saw to cut the slats off of both sides of the wood pallet, then use a Double End Nail Puller to remove the nails from the center wood brace of each pallet.

(2) Place the Particle Board on Sawhorses, select the straightest Pallet Slats and lay them on the Particle Board in the desired design. Use a Circular Saw to make any needed cuts.

(3) Remove the Slats to paint the Particle Board the desired color of the Pallet Slats.

(4) Cover Particle Board with Wood Glue, place the Pallet Slats on the board in the desired design, then secure each side of the Bar with clamps and allow dry time.

(5) Paint the Slats attached to the bar top. Make sure all sides and cracks have been painted. Allow the paint to dry before moving on to the Epoxy Resin Finish.

Additional Steps for the Pallet Shelf:

(A) Match the size of Particle Board for the shelf to the exact size of Pallet Slats then follow steps 1 thru 4 above.

(B) To create a clean edge or molding around the pallet shelf cut pallet slats in half lengthwise with a Jigsaw.

Epoxy Resin Finish:

Most importantly, allow three days for this process. It is best to complete the finish in a garage or another ventilated dust free space.

(6) Completely cover the floor under the Sawhorses with a drop cloth to protect the flooring. If desired, add a drop cloth over the Sawhorses as well.

(7) Place the Pallet Bar Top (and shelf) on Sawhorses.

(8) Follow the instructions on the Epoxy Resin to mix. Pour the Resin over bar top & shelf, then use a Putty Knife to level the coat of Resin. If noted, use a blowtorch to remove air bubbles from the finish.

(9) Over the course of the first few hours, wipe the underneath side of the bar top where the resin runs off to ensure an even surface absent of drip lumps.

(10) Allow three days (or as directed by the Epoxy Resin Instructions) for the Epoxy Resin Finish to cure.

3 days later… MOUNT IT!!! Finally.

Mount Brackets to wood studs in the wall. Place bar top and shelf onto brackets. Secure both using wood screws by driving them through the bracket holes into the Particle Board on the underneath side. Then pull up a barstool and have a drink.