Build Your Own Eco-Friendly Foldable Pallet Chair in Simple Steps

ATC DESIGN
Nov 15, 2025
3 min read

Updated: Nov 23, 2025

Are you searching for a seating option that combines style, function, and sustainability? Building a foldable pallet chair from recycled wooden pallets offers a smart solution.

This DIY project not only helps reduce waste but also gives you a unique piece of furniture perfect for your garden, patio, or camping adventures. The chair folds flat for easy storage and transport, making it both practical and eco-friendly. Let’s walk through the process of creating your own foldable pallet chair with clear, step-by-step instructions.

Foldable pallet chair crafted from recycled wood, ideal for outdoor relaxation

Materials Needed for Your Foldable Pallet Chair

Before starting, gather all the materials to ensure a smooth building process:

Wooden pallets: Choose heat-treated pallets that are safe and sturdy. Avoid pallets treated with harmful chemicals.
Sandpaper: Use 80 grit for initial smoothing and 120 grit for finishing touches.
Wood screws: Select screws designed for outdoor use if you plan to keep the chair outside.
Heavy-duty hinges: You will need 6 to 8 hinges depending on your design to allow the chair to fold.
Screwdriver or drill: For assembling the parts securely.
Measuring tape: To get precise dimensions for comfort and stability.
Wood stain or paint (optional): To protect the wood and add a personal touch.
Paintbrush: For applying stain or paint evenly.
Wood glue (optional): Adds extra strength to joints.

Having these materials ready will make the building process efficient and enjoyable.

Step 1: Prepare the Pallets

Start by carefully disassembling the pallets. Look for planks that are free from cracks, splinters, or warping. These will form the main parts of your chair.

Use a crowbar or hammer to gently take apart the pallets without damaging the wood.
Sort the planks by size and quality.
Sand each plank thoroughly. Begin with 80 grit sandpaper to remove rough edges and splinters, then finish with 120 grit for a smooth surface.
Pay special attention to edges and corners to ensure safety and comfort.

This preparation step is crucial for a durable and comfortable chair.

Step 2: Construct the Seat and Backrest

Next, assemble the seat and backrest from the prepared planks.

Seat: Arrange planks side by side to create a rectangular base. The typical seat width ranges from 18 to 22 inches, depending on your preference. Secure the planks together with wood screws, placing screws evenly to avoid splitting the wood.
Backrest: Build a slightly shorter rectangular panel for the backrest. This should be tall enough to support your back comfortably, usually around 20 inches high. Attach the planks similarly with screws.

Make sure both parts are sturdy and aligned properly to ensure comfort and stability.

Step 3: Attach the screws

The folding feature depends on how you connect the seat and backrest.

Position the heavy-duty screws evenly along the joint where the backrest meets the seat.
Attach the screws securely with rings and bolt, allowing the backrest to fold flat against the seat.

Test the folding mechanism several times to ensure smooth operation without resistance or wobbling.

Proper hinge placement is key to making the chair easy to fold and unfold.

Step 4: Build the Legs and Frame

For stability, the legs should form an “X” shape.

Cut four wooden pieces for the legs, ensuring they are equal in length.
Assemble the legs into two “X” shapes by crossing two pieces and securing them with screws at the intersection.
Attach the “X” shaped legs firmly to the underside of the seat base.
Check that the legs open and close smoothly with the folding seat and backrest.

This design provides strong support and allows the chair to fold compactly.

Step 5: Finishing Touches

Once the chair is assembled, consider these finishing steps:

Apply wood stain or paint to protect the chair from weather and wear. Choose a color that complements your outdoor space.
Use a paintbrush to apply an even coat, allowing it to dry completely before use.
Optionally, add a layer of wood glue at joints for extra durability.
Add rubber or felt pads to the bottom of the legs to prevent slipping and protect surfaces.