Inspiration can be found all around us. This Butcher Block Style Pallet Computer Desk is a great example. It was made from over 120 salvaged pallet planks found at work and is made taller and deeper to be a comfortable gaming table.
Butcher Block Style Pallet Computer Desk:
First, I carefully removed all the nails, trimmed and sorted everything out. Next, I glued the pallet planks with the nicest side facing on the bottom. This took two us about twenty minutes to spread the glue onto all the planks. We let it dry for 48 hours after clamping it together. Next, we began trimming it. I did the first cut at 32" using a circular saw to remove the uneven planks. This lets me check to see if I did a good job of the gluing process. The next cut was to trim off the rough edges on the opposite side. Then we cut it to the dimensions we wanted. Additionally, we used a Makita hand-planer to get a nice even surface on both sides.
Finally, we filled in the gaps with glue and sawdust mixture.
Butcher Block Style Pallet Computer Desk Finishing:
We did the first sanding using an 80 grit sandpaper to get everything nice and smooth. Then we finished it with 120-grit paper. We made the table legs out of four rectangular tubular metal pieces that were 2" x 4" x 27" and 1/8" thick, as well as four flat 3/8" x 4" x 24" metal plates. I welded these pieces into rectangles. One flat metal was drilled to attach the table top to it, and the other flat metal is on the floor. I did the welding with a Lincoln 180 Migpak and 0.35 Fluxcore wire.
I primed and painted the metal table legs the next day. For additional support, I added a thick plank in the middle of the tabletop on the underside, to prevent any shifting. I attached the legs to the table with 3/8" screws.
We used a matte acrylic varnish and applied a total of four coats.
For a first table, I am "OK" with the result, some imperfections, but the desk feels great and sturdy enough to hold the three monitors I will be purchasing soon.