How I made this fun Hurricane Pallet Bar:
I built this out of two old canopy end-pieces. Hurricane Ike tore up this canopy several years ago. I used all recycled wood for the structure, and most were oak pallets. I chose oak because I particularly love the rugged look. I didn't sand or stain, other than removing any rough, splintery areas.
I built the bar so that it incorporated the canopy supports. I just drilled out to create half-circles on each piece of the board where they joined. This was both for support and for visual interest. I designed and cut the ends of the bar into angles. I made a comfortable and exciting bar top, so no one gets poked by the corners.
I built the canopy with a steep pitch so that water runs off quickly, and made the "shingles" out of pallet wood as well. I cut some of the boards down so that I could stagger the shingle joints as much as possible to extend the roof life. The canopy fits in with the shape of the space it is in, as well as providing a good amount of shade. I left the ends of the canopy open so that if I grill on it, the smoke has a place to escape. I'm just careful to insulate any table-top grill from the wood by placing it on bricks to prevent any damage or worse. I like the outcome of this project, and I'm looking forward to hosting gatherings and parties out around my pallet creation. I hope you all like my Hurricane Pallet Bar!
I built this project in about three days, and I used 15 pallets.