Pocket doors are beautiful, but they’re expensive and challenging to retrofit to a home. Instead, make a beautiful, handmade Sliding Pallet Interior Door. It’ll eliminate the issue of small rooms and door clearance issues!
Tools & Supplies Needed:
Locate and obtain quality pallets that are mostly intact and clean. If you’re not sure the pallets you have are safe, check out our Pallet Safety article! First, find some usable pallets. Refer to our Pallet Safety page if you’re not sure you should be using them or not.
Using a reciprocating saw with a metal blade, cut between the joint of the pallet planks and stringers. Be sure to use eye, hand, and arm protection. When completed separate out the quality pieces from those that are not able to be used. Remove the deck boards using a reciprocating saw. Optionally, you can remove the nail heads or not. If you do, you can use a nail setter/punch & a hammer. Next, start sanding!
Use a thin sheet of maple, pine, or oak plywood to attach the planks to it. Using the plywood will ensure privacy if there are any gaps in the wood due to warping or bending. Stain the plywood the same color that you plan to use on the pallet wood after cutting it to the dimensions needed. If this door will divide two rooms, use a good-quality, attractive-looking piece of plywood.
Cut the pallet pieces to the width needed for door opening. Sand them with 60 or 80 grit sandpaper. Be sure to sand the front and back so that the stain and glue both have clean surfaces to be applied to. Sand your boards down to the smoothness you desire. If you prefer it more rustic; that’s fine!
Now that you’ve prepped your boards let’s start building!
Place horizontal pallet pieces down on the plywood, applying wood glue to the back of the planks. Ensure a 90-degree angle is maintained after each plank is placed with a square. Glue the boards down in place. Check for square FREQUENTLY! Notice the previously-stained plywood. Use a good quality wood glue for this job.
Cut and place 1″x 6″ border pieces in. Secure with screws, being careful not to extend the screw beyond the back of the plywood. Once the 1×6 pieces are secured, carefully flip the door on its face and place screws from the backside to ensure a tight fit of all of the boards that have been put in place. Install your trim/border boards in place with screws. Pre-drill to prevent splitting the wood.
Complete the trim boards.
Turn the door over to its back again. Measure cross pieces and secure with a screw on each end and in the middle. If more securing is desired, you will secure from the back side to hide the extra screws placed. Begin adding your cross pieces to the door.
All the cross pieces are done!
Stain the door using a foam brush for hard to reach joints and a cloth for surface applications. Allow to dry and repeat another coat. Seal the entire door (front and back) with 2-3 coats of polyurethane. Stain or paint your door any way you choose.
Install painted header board. Ensure an adequate number of studs are used to secure the header board as this will carry much of the weight of the door. Install the door track per the instructions. Install the slider hardware. I previously painted the long trim board beneath the slider rail. Be sure you find studs to attach this piece to the wall as it supports quite a bit of weight.
Installing the hardware for the door hangers/sliders. Follow the manufacturer’s directions.
Finishing up!
Hang door and install remaining hardware (bumpers, floor guides, privacy hook). My completed Sliding Pallet Interior Door! I think it looks great, and it’s practical!
Now for some decorating – make yourself a Garden Hose Basket!
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View Comments
This is stunning! What a great idea. Pallets are wonderful and the ideas are endless!! Great job
Chris O'Meara, perfect for the bathroom pocket door!!
Scott Coleman?
Kinda what I was thinking!
That would be neat for bathroom door lovey!
COOL! Glad this project is inspiring you. If you end up making this, we still need some Stanley Hardware builds from U.S.-based crafters. All you would have to do is to draw up a quick sketch of your idea and give us a rough idea of the dimensions (hand-drawings are fine). If it is one of the several projects we still need to be built, you can get all of the hardware FREE! You can use the "Contact Us" button if this would interest you. Thanks, and Happy Palleting! Heather the Admin Assistant.
Nicolas Maguire for the bathroom
Mike Genovese I love this door!!!
Awesome!!
yeah right if I get a door I'll be lucky.
You could make an entire kitchen with pallets
Rachel Maxwell me too
Love it!
I just went to tag you also haha
They look amazing
wayyyy cooool.... lets do that for the kitchen door