This rustic pallet door was made from 2 pallets and (3) 2"×6"×8" timbers, we wanted to keep this door simple and rustic. So we measured the original door for our measurements then cut the 2"×6"×8" timbers to size for the door frame.
We cut our pallets to fit, we planned the pallets and then trim the pallets with a router to round-over corners. We left most of the nail holes to add to a rustic look.
We then drilled our holes for the dowels to help strengthen our frame, we use plenty of wood glue also. After fitting pallets in our frame, we added trim boards. We stained the door with a mix of special walnut and mahogany for a color we decided on. The door is weather sealed but no clear.