Pallet bed

So I had this crazy idea and finally got Phil on board to build a pallet headboard for the guest room.  Little did I know he was going to take this project to a whole new level.  I thought, a couple pallets, a couple screws, some plywood and stain...and of course whitewash...and I'll be done.  Easy weekend project right?  HA

Below is our process - if you want to skip all the steps and check out the materials list, scroll all the way to the bottom.

We received free pallets from our flooring vendor.  Phil used a reciprocating saw to cut the nails instead of trying to remove them piece by piece.  We got this idea from: http://www.thinkingcloset.com/2014/02/24/so-you-want-to-build-a-pallet-headboard/ (I'm not one to steal great ideas/suggestions)

Next he separated all of the pallets into color/size:

As my hubby says, if you're going to do something, you've "got to do it right".  Hence, the frame made out of 2x4:

This is a queen size bed frame.

My suggestion would be to build your frame at least 6" wider than your mattress and the heigh of ours was 5'.  Mattress measurements can be found at: http://www.beddingexperts.com/mattress-sizes-chart/ 

So, now you've got to sand and stain the frame before you can start building.  While he was having fun with that (lol), I decided to lay out the pallet design.  

Once the frame was dry, we began laying out the pallets, measuring, and cutting to size.  Phil counter sinked (sunk?) each screw so that took a bit of time, then I went back and filled each hole with wood putty afterwards.

Here is a picture of the final unsanded and sanded product. Look at the difference in color!  I went over it twice with 60 grit and once with 100 grit...soft as a baby's bottom now :-)

 unsanded                                  

  sanded (we also added a shelf)

After using our dryvac and a clean rag to get all of the sawdust off the piece, we used Minwax Provincial 211 for the stain.

We followed the same steps for the footboard - here's a picture of the back.  We had to sand and stain both sides since you will see this when you're laying in bed.

We purchased a sturdy metal frame from a local mattress store for $70 and purchased 5/16 bolts, washers, and nuts to attach the frame to the bed.

And voila - our finished product (the light is also home made with vintage antique finds and a lighting kit from Lowes).  

BTW, do you see something missing?  Yes, I was not allowed to whitewash the bed.  Totally outvoted but now I think he was right.  It's gorgeous just how it is.

Materials list:

1. Reciprocating saw (to cut pallets apart – easier than pulling and breaking each piece of wood) - watch the link above
2. Compound Miter saw - or you can use a circular saw if you’re good at straight lines
3. Hammer
4. 1 inch screws
5. wood putty
6. 60 grit and 100 grit sand paper
7. Palm sander
8. Stain – we used minwax provincial 211
9. Six 2x4 for the frame (for headboard).  You’ll need 3 more if you’re doing a footboard (height 26” by length 63”).
10. Measuring tape
11. Sanding respirator (mask) - it’s going to get dusty when you’re sanding!
12. eight - 5/16 bolts, washers, and nuts if you purchase a metal frame (make sure you buy one that has head and foot board connections

GOOD LUCK and have FUN!