If you want to learn how to build a rustic cooler from pallets then I’ve got a great project.
And the coolest part is that I did it using only one type of saw.
There are great tutorials on the web but they all require a ton of tools.
I know you might not have a table saw, router or miter saw – which can cost hundreds of dollars.
That’s why I made this tutorial. To show you that you can build a rustic cooler with only a few tools.
I used a drill & impact driver plus the Dremel Ultra Saw.
I’m super excited to show what the cooler looks like and I’ve got a way cool surprise at the end!!!
Some of my fans know I make a weekly trek to Lowe’s for supplies.
This past Saturday I discovered the Ultra Saw while sauntering past the tool section (think Shaggy from Scooby Doo).
After checking out the description I was all in and decided to get one, specifically for this project.
You’ll see why I fell in love with it.
Here’s a list of all the supplies for the rustic cooler
- 5 to 8 Pallets (FREE)
- Power Washer (optional if wood is scrubbable)
- Dremel Ultra Saw ($129)
- 50 Quart Cooler (FREE or $29)
- Impact Driver or Drill (FREE)
- Measuring Tape (FREE)
- Pencil (FREE)
- Flat Head Screwdriver (Free)
- Pliers (FREE)
- Hammer (FREE)
- Pry Bar (FREE)
- Exterior Wood Screws (2 boxes of 75 at $8/Box)
- Titebond Wood Glue ($4)
- Elevator Bolts ($4 for 4 – 5/16 inch x 2 inches)
- T-Nuts ($4 for 4 – 5/16 inch)
- Hinges ($6 for 2 – 3 1/2 inch square hinges)
- Speedbor Drill Bit ($8 for 1 1/4 inch diameter)
- Hose Bibb ($7 for 3/4 inch)
- PVC Coupling ($1)
- Handle ($3)
- Bottle Opener ($9 – optional)
- Bottle Cap Catcher ($10 – optional)
- Beer (you pick the price, haha)
If my math is right the materials cost $72. That includes the optional bottle cap opener & bottle cap catchers – which cost $19.
After you read or watch the tutorial you’ll be able to make the cooler in one day. Okay, maybe a day and a half if you take pool breaks like me.
Seriously, I started Saturday morning then went to the pool with my daughters and wife for the afternoon. We did the same thing on Sunday but I finished the cooler by 6 pm on Sunday. If I can do this you can too!
Here’s what you’ll learn
- How to build an awesome rustic cooler using pallet wood
Let’s get started on this bad boy.
How to get pallet wood for FREE and prep it for your rustic cooler
Here’s what I discovered: call your local landscape supply company to get free pallets.
They’re super nice and willingly to part with pallets.
Big box stores get paid $15 to $20 for their pallets and this is why they don’t give them away.
Pick out 5 to 8 pallets whose wood slats are in good shape. The slats on my pallets were 5/8 of an inch thick.
Either hose the pallets down or power wash them.
Power washing the slats made a huge difference in the appearance.
If you can, choose pallets like the ones in the picture below. Slats were attached to only two boards.
Remove the slat by sawing it off on either end.
You can use the Ultra Saw to saw off any stubborn nails or screws, too (pretty sweet).
I used a 50 quart Igloo cooler for this project and dry fit the slats to see how many I’d need to cut.
Remove all the hardware from the cooler: handles, wheels, hinges, latches, etc.
Now it’s time to start building the rustic cooler legs and frame.
Building the rustic cooler’s frame – it’s easier than you think!!!
I’m not the first person to build this kind of cooler.
Heck, I don’t even think mine is the best.
But I can promise you it’s the simplest to build.
Many tutorials use all sorts of tools that cost upwards of $1000.
So I decided to make a cooler that only required a few tools.
You need to build 4 legs. I did this by cutting 8 slats to 33 inches in length. Attach 2 slats together at a 90 degree angle using wood glue and wood screws.
Pre-drill all your holes so that the wood won’t splinter.
Place two legs on top of the cooler and measure the distance between them. Then add the width of two slats to this measurement. This measurement is for the slats that make up the sides of the cooler.
Now measure the height of the cooler and figure out how many slats you need – in my case it was 6 slats for each side for a total of 12 slats.
You’ll want enough slats to cover the entire height of the cooler plus an extra 4 to 5 inches.
Cut those slats to size using the Ultra Saw then place two legs on the ground.
Here’s a little tip: look at how the legs are positioned on the ground and make sure they’re all oriented in the same fashion. This is a small aesthetic preference but will affect the look of the cooler once it’s finished.
Apply wood glue to the legs, position the slats between the legs, pre-drill two holes on each side of the slats, and screw the slats to the legs.
Since my slats were 5/8 inches thick I used 1 1/4 screws so that the screws wouldn’t protrude through the face of the slats.
I initially used 1 5/8 inch screws but that didn’t work out so well!!! The ends of the screws went through the slat faces. I want people to get a beer from the cooler NOT TETANUS.
Do the same thing to build the other side of the cooler.
Place the cooler upside down on a flat surface. Position one side flush against the cooler. Place a slat flush with the front of the cooler and against the side piece. Place a second slat flush with the other side of the cooler. Mark the intersection between the front slat and second slat. This is the measurement for the front and back slats.
Cut one front slat to size and dry fit it between the two sides to check the cooler will fit.
Once you’re sure the front slat measurement is accurate go ahead and cut 12 slats, 6 for the front and 6 for the back.
Attach 6 slats one on top of the other to the left and right sides. Add wood glue, pre-drill two holes on each side of the slats and screw them to the legs just like you did with the sides.
When you’re done you’ll have the rustic cooler frame. Dry fit the cooler into the frame. It will be nice and snug.
The next step is to build a little shelf for the top of the cooler frame.
Making the shelf and lid for the cooler, easy peasy
Keep the cooler in the rustic frame and place the frame on a flat surface right side up.
You’re gonna build a little shelf on top of the frame so that the lid closes easily and the frame looks a bit nicer.
This is super easy.
Measure the distance between the outside edges of the front legs. Cut a slat to this size.
Do the same thing for the back legs.
Add glue to the top ledge. Place the front and back slats onto the top of the frame. Pre-drill holes into the slats and screw them down.
Measure the distance between the front and back slats. This will give you the measurement for the side portions of shelf. Cut those slats to size and attach them to the cooler frame like you did in the previous step.
I wanted the side shelf pieces to be slightly skinnier than the front and back. So I made a rip cut using the Ultra Saw. It worked out beautifully.
With the shelf in place, you can frame the lid.
I placed the cooler lid on top of the cooler and basically built a box around it.
To see how I did this and gave the rustic cooler adjustable legs watch my video tutorial.
I’m super stoked about the legs since our patio isn’t exactly level. It’s a small detail that other rustic coolers didn’t have and I thought it’d be a sweet option. Plus I added a few other cool accessories.
Here’s the final product.
Not too shabby
If I can do this you can too.
Many thanks to Lowe’s for their continued support and making me a Lowe’s Creative Ideas blogger.
They provided some clams for this project but the carpentry and beer drinking tips are from me.
You can get more inspirational home improvement ideas by clicking over to the Creative Ideas website. Here’s the link http://www.lowes.com/creative-ideas.
If you’re a Pinterest fan, Lowe’s also has a ton of pins for home projects (3,545,565 people like their boards and I’m guessing you might too).
A Fathers Day Gift for a Cool Dad
Father’s Day is next week.
To show my appreciation for a Dad who doesn’t mind getting a bit dirty I’m giving away a Dremel Ultra Saw.
I love this little saw because it’s perfect for all sorts of projects. Like cutting door trim, removing paint, and building a rustic cooler (haha).
I’m pretty sure you’ll like the Ultra Saw as much as I do. It comes with 4 different blades and a nifty carrying bag. Perfect for any Dad who’s handy.
To win, leave a comment on this post by the end of Sunday June 8 (11:59 p.m. 6/8/2014) and tell me about a project you have that could use the Ultra Saw.
Super simple. I’d love to see you win so feel free to elaborate a bit and spill the beans on your upcoming DIY adventure.
The winners will be announced on Facebook and within this post on Home Repair Tutor.
Thanks again for reading and watching, I really love hearing from you. See you in the comments.
P.S. Congrats to Anne, she was the winner of the Ultra Saw. Many of her tools were stolen and a lot were from her late father & husband. She uses her talents to build gifts for friends and those in need. She’s a true inspiration to all of us DIYers.