Making an outdoor coffee table out of pallet wood and an old planter base

Tools and materials I propose:

Table saw

Angle grinder

Metal cutting discs

Random orbit sander

Stick welder

Cordless drill

Cordless Impact Driver

Bandsaw

Jigsaw

Router

Router bits

Air compressor, nail and staple gun kit

Block plane

I made this coffee table out of an old metal planter base, some pallet wood and a piece of 9mm plywood. It's kind of semi rustic and I think it is ideal for having it outdoors on your garden or balcony.

I begun by cutting some excess metal from the planter base using the angle grinder. I then cut four square pieces of steel. These would help me screw the table top on to the base. 

I started removing the paint with a sanding disc. But then I decided to use paint remover. I applied the remover and let it sit for a while. Then I scrapped the paint off with wire brushes. 

At this point I stick welded the four square pieces on the base. I welded two points at first and then I finished the seam. I welded the pieces from both bottom and top sides. 

I cleaned the welds with a sanding disc and then I drilled the holes for the screws. 

Finally I painted the piece black with two coats of oil paint. 

Now for the woodworking part. First I drew a circle on a piece of plywood. I drilled the centre and then drew another circle on it’s back. 

I used the router with a straight bit and circle cutting jig. I cut the plywood circle. 

Then I used the table saw to cut my pallet wood to size. I then glued and nailed the wood on to the plywood. I used the bandsaw and a jigsaw to cut the excess pallet wood off. 

I used the circle cutting jig again to to remove some more pallet wood. Then I trimmed everything flush with a flush trim bit. I did that because my bits were sorter than needed to do the job at once. 

I cut some thin pieces of spruce on the table saw to cover the end grain. Then using glue and flat headed nails I bended the pieces to place.  To avoid splitting the wood, try not to add the nails in a straight line. To the points were two pieces connected I tried to place the nail in the middle. This way the nail’s head forced the wood in place. Just to be sure I clamped the piece with a band clamp and let it sit over night. 

I then used a block plane to plane the edge band flush.

I then sanded the piece. I tried to leave as much pallet look as possible. This wasn’t supposed to be super clean.

Finally I applied four coats of clear water based varnish and then screwed the top on the base. 

I am really happy with the way it came out. I think we are gonna enjoy this table on summer. But that was it. See you soon with a new project video. 

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