He Upcycles Old Wood Pallets Into Perfect-Sized Patio Chairs With Charm
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A DIY with Andrew video shows a patio lounge chair made from reclaimed wood from one pallet, using basic tools and screws. A follow-up video supplies exact measurements after viewers sought more detail; the original report also advises sealing the porous wood for outdoor use.

A video by DIY with Andrew shows how to turn wood from one old pallet into a patio lounge chair, offering a lower-cost route to outdoor seating for people who can source reclaimed wood and already have basic tools. Hunker reports that a follow-up video provides exact piece measurements after viewers asked for more detailed build instructions.

The project starts by taking the pallet apart with a pry bar and hammer, then sanding the boards and measuring and cutting them to size. The chair is assembled with a drill and wood screws. Hunker says the build is not especially demanding, but it is not a quick project; the report does not give a total build time or a tested cost.

In the video, Andrew uses four slats for the seat and three for the backrest. He cuts notches in the seat slats so they fit around the armrests and back supports, and uses a speed square to set the angles for the supports. Hunker estimates from the video that the back may recline by about 15 degrees, while recommending a 10-to-15-degree range for a lounge chair; that angle is an interpretation, not a confirmed measurement from Andrew.

The source notes that pallet boards can split because they are thin, and says Andrew pre-drills screw holes before assembly. Hunker also says the original video did not show a paint or stain finish. It recommends applying an outdoor wood finish or sealer, with reapplication depending on the product and condition of the wood.

At a glance
reportWhen: Reported by Hunker; the source does not…
The developmentA DIY tutorial and follow-up measurements show how reclaimed pallet wood can be assembled into a patio lounge chair.

A Lower-Cost Route to Outdoor Seating

The build gives viewers a way to reuse pallet wood rather than buy ready-made patio chairs, which can be costly when several seats are needed. Hunker describes the chairs as potentially close to free if the pallet and basic tools are already available, but that is a conditional estimate: the source does not provide a full budget, and the project still requires screws, sandpaper and time.

The report also highlights practical limits behind the low-cost pitch. Pallet wood needs to be inspected, sanded and protected from weather, and the original tutorial initially lacked measurements that viewers wanted. The follow-up makes the instructions more usable, but the source does not report independent testing of the chair’s durability, comfort or weight capacity.

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From Pallet to Patio Chair

Hunker’s report describes a project demonstrated in a YouTube video by DIY with Andrew. The footage shows the main stages—disassembly, sanding, cutting and assembly—using reclaimed pallet boards. The article says the creator appears to have a pile of pallets and may be planning a set, but it does not confirm that a full set was completed.

Viewers raised concerns about missing build details, according to Hunker, prompting a second video with measurements for each piece. The report advises noting those dimensions before starting, so builders do not have to switch between videos while working. It also recommends weatherproofing because reclaimed wood can be porous and prone to cracking.

“This project is not demanding and only requires a few tools.”

— Hunker, describing the project

Build Cost and Durability Remain Unclear

The source does not state the chair’s exact dimensions in the original video, the full project cost, or how long construction takes. Hunker says the follow-up video contains precise measurements, but the supplied report does not list those measurements. It is also unclear what type or condition of pallet wood was used, whether the finished chair was tested for weight capacity, or how it holds up after extended outdoor use.

The estimated recline angle is based on Hunker’s interpretation of the footage. The report’s suggestion of a 10-to-15-degree angle is advice, not a confirmed specification for Andrew’s chair. The source also does not identify a specific sealer as mandatory or provide a maintenance schedule that applies to every product and climate.

Check Measurements Before Cutting

Anyone following the project should consult the follow-up measurement video before cutting boards, as Hunker says it provides dimensions missing from the original tutorial. The next practical steps are to check the pallet boards for damage, remove nails, sand the pieces, pre-drill screw holes and apply a suitable outdoor finish. Hunker says a topcoat may need renewed every few years, while a penetrating marine-grade sealer can be reapplied when water no longer beads on the surface; actual care depends on the product and exposure.

The report does not announce a further video, a completed set of chairs or independent testing. Any additional build details or performance information would need to come from the creator or a separate evaluation.

Key Questions

How many pallets does the chair use?

Hunker says the demonstration makes a chair from one old pallet. The amount of usable lumber can vary with the pallet’s size and condition.

What tools are needed for the build?

The report lists a pry bar, hammer, sander, tape measure, jigsaw and drill, along with wood screws. It also says Andrew uses a speed square to measure support angles.

Are the exact chair measurements available?

Hunker says a second YouTube video gives the exact measurements for each piece. The supplied report does not reproduce those dimensions, so builders should check that video before cutting.

Does the chair need a protective finish?

Hunker recommends weatherproofing pallet wood because it can be porous and prone to cracking. It discusses topcoats and penetrating marine-grade sealer, but the right product and upkeep depend on the wood and outdoor conditions.

Source: hunker.com

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