Like most of you, I have a backyard shed, but as my hobby interests grew, so did my collection of tools. I found myself building pallet carts for my power tools, so they were on wheels, which helped considerably, but I still always needed “the tool in the back of the shed.” This situation meant I had to unpack my shed daily for various projects. We came up with an idea to get around that issue by making my own Pallet Barn Stall Tool Shed. I was able to do this because of the Stanley Hardware sponsored program 1001pallets.com offered to all the U.S. crafters.
Although I’ll describe my project in detail, you’ll have to adapt the idea to fit your yard and tool needs. You will most likely have to frame your structure differently. Use my project to plan out your own custom “Tool Barn” as we call it now. Be sure you check with our local code enforcement or planning/zoning department for requirements on sizes, easement requirements, etc. for sheds in your area.
Make your own handy Pallet Stall Tool Shed – Tools & Supplies needed:
- Ground-leveling tools (shovel, pickaxe, rake, wheelbarrow, straight long board, 36” bubble level, rototiller, etc.)
- Personal Protective Equipment (safety glasses, respiratory protection, gloves, hearing protection, etc.)
- Brad Nailer/nail gun & brads
- Air Compressor (to power brad nailer)
- Rubber mallet
- Reciprocating Saw (we used a Milwaukee Sawzall with a Diablo Metal/Wood Blade)
- Drill & various-sized bits
- Impact driver
- Socket set and hand wrenches for hardware
- Table saw
- Circular saw
- Chop/Miter saw
- Random-orbit sander or palm sander
- Wood clamps (any variety you prefer)
- Wood glue
- Construction adhesive (We used 3M Grab-It)
- Caulking gun
- Painting supplies (brushes, roller, tray, can opening tool, drop cloth, etc.)
- Wood screws (exterior)
- Step ladder (if you’re short like me, haha)
- Radio, knee pads, or kneeling pads (not required, but makes an outdoor summer project in the dirt more pleasurable!)
- 69 Cement pavers. We used 12” square ones available at the local home centers. You could leave your floors bare, cement them, or create a wooden floor
- 4×8’ sheets of plywood or another sheet wood-like Chipboard – we used plywood/chipboard for the rear wall and pallet wood for the remaining exterior pallet walls
- Pallet wood: 1×4” boards, 1×6” boards, 4×4” posts (stringers), and 2×4” (for doors and part of the frame)
- Upcycled patio beams: 3”x3”x24’ boards (qty approx. 8 total) – rear wall frame, roofing frame, and parts of other walls
- Roofing material of your choice. We used Ondura Corrugated Asphalt Panel remnants & Ondura nails – follow Ondura’s installation directions
- Hinges (2 per door)
- Handles/door pulls (1 per door)
- Corner brackets (4 per door)
- Lockable twist-lock hasps (1 per door)
- Washers/Exterior galvanized hex-head screws (to hold brackets in place)
- 24” metal magnetic strips (6)
- Shelving brackets (12)
Planning & Revamping Plans For My Pallet Tool Shed:
First, we decided on the size of the shed we needed. Originally I wanted more stalls, but wall thickness and cart sizes built for the tools meant I had to modify my plans. I ended up making more doors, which I like better than my original plan!
Prepping the yard…where was a Bobcat when I needed one?
Begin Installing Pavers (or flooring) of your choice.
We used 12”-square, 1.5” thick standard pavers you can get at home centers for under $1.00 apiece.