Harvest Pallet Wood the Easy Way

Updated on March 29, 2019
mgeorge1050 profile image

Alan enjoys woodworking and has a special interest in rustic home decor. He has been involved in woodworking for over twenty years.

Nailed It!

Using a reciprocating saw to cut around the nails is the quickest, easiest way to harvest small pallet wood planks. Pallets are built to last using hard woods and special nails. Those nails normally have a ringed shank, making them very difficult to pull out. The nearly indestructible quality of pallets is great for cargo shippers, but not so great for someone wanting to use some of that beautiful pallet wood for a project.

Pallet Wood Key Holder

Pallet wood has a rustic look with tons of character.
Pallet wood has a rustic look with tons of character.

Let's Get Started

There are many methods out there for harvesting pallet wood, but none of them are quite as easy as this one. If all you need are smaller pallet planks for your upcoming project, there is no reason to try and pull pallets apart. It is very labor intensive, and it often cracks the pallet wood in the process.

First, make sure you have all of your materials ready.

  • Pallets with plenty of unbroken planks.
  • A proper saw, preferably a reciprocating saw.
  • Saw blades that will cut both wood and metal.
  • A clear, sturdy floor space in which to work.
  • Personal safety gear like gloves,safety glasses, and proper footwear.

Then just follow these simple steps and your pallet wood project will be well on the way to completion.

  1. Choose a pallet with several nice looking planks.
  2. Place the pallet on solid ground and use one foot to hold it steady.
  3. Use a reciprocating saw to cut the planks away from the ribs.
  4. Collect the freshly harvested pallet wood planks.
  5. Sand pallet wood planks to remove any splinters and grime.
  6. If necessary, cut the plank ends square for easier use.

Safety First

Never try this method with a circular saw, as kickback of the tool is inevitable.

Work Smarter Not Harder

The obvious solution to the always problematic pallet nails is simple, remove the nails from the equation! Use a reciprocating saw, or what many people call a 'saws all', to cut the pallets apart. This method avoids the nails completely, but does only produce smaller pallet planks. If your project calls for boards around sixteen inches or smaller in length, then this is the method for you.

Four Section Pallet Wood Crate

Why Pallet Wood?

Why Do You Prefer Pallet Wood For Your Next Project?

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Reciprocating Saw

The Right Tool for The Job

A reciprocating saw with a good blade is definitely the right tool for this job. Choose a blade that works on both wood and metal, as striking a nail during the process is not uncommon.

A jig saw could also be used, if a reciprocating saw is not available. Never try this method with a circular saw, as kickback of the tool is inevitable. This is an important safety issue, and should be respected.

A reciprocating saw blade made for wood or demolition work does very well with pallets. After twenty plus years of woodworking, I have come to prefer DeWalt blades like these. They last much longer and do not bend as easily as the cheaper blades.

A pruning blade is fast, but makes a little rougher cut. As these initial cuts are not normally the final cut, this is usually not a problem.

Saws for Cutting Pallets Apart

Tool
Pros
Cons
Reciprocating Saw
Easy to use, powerful, fast
Costly tool
Jig Saw
Easy to use, no kickback
Less power, slower
Circular Saw
No pros
Dangerous, kickback, not advised

The Work is Almost Done

After cutting each plank away from the ribs, the harvesting work is done!

Reciprocating Saw Safety

Cut Out Pallet Planks

Harvest The Pallet Planks

Most all pallets have planks across the top and bottom, with larger wooden ribs between the planks. The planks are nailed to the ribs in a perpendicular fashion. Start by laying the pallet flat on the ground with the best planks facing up. Put one foot on the pallet to hold it steady. Be careful to keep your foot far away from the saw at all times.

Cut each plank right next to the ribs, leaving the nails and small pieces of the planks attached to the ribs. Use the photo below as a guide. The red lines show where to make the cuts, and some parts are labeled in green. The planks are what we are after here.

After cutting each plank away from the ribs, the harvesting work is done! Collect all of the pallet wood planks and throw the nail filled ribs in the campfire.

Cut The Pallets On The Red Lines

Finishing Touches

When the pallet cutting is finished, the resulting planks can be used right away. This usually creates a very rustic look. This includes rough cuts on the plank ends and major splinters. To make the pallet wood a little easier to work with, take two simple steps.

First, sand the pallet wood heavily to remove grime and splinters. Pallets are made with very roughly cut lumber, and the splinters are plentiful. A good sanding will make the pallet wood much easier to work with.

Second, cut the ends of each plank square. A miter saw works great for this step. The pallet wood planks will be smoother, safer, and squared off. That means easier measurements and cutting for the upcoming project.

Once the project is finished, stain the pallet wood for a real professional look and feel. The stain will also make the freshly cut ends blend in with the more weathered surfaces. I prefer a lighter stain, as the darker stains tend to cover up most of the grain. Finish up with the clear coat of your choice and enjoy your new rustic home decor!

Pallet Wood Key Holder

This content is accurate and true to the best of the author’s knowledge and is not meant to substitute for formal and individualized advice from a qualified professional.

Questions & Answers

    Comments

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      • mgeorge1050 profile imageAUTHOR

        Alan 

        8 months ago from West Georgia

        Pallet projects can be labor intensive at times, but I'm glad it worked out well in the end. Thanks for the comment.

      • profile image

        RTalloni 

        8 months ago

        It took some convincing but my husband finally agreed to a pallet project last fall. He was glad he had the reciprocating saw and was surprised at how nicely his project worked out.

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