Last Updated on September 16, 2024 by John Coleman

Who says you need a fortune to create the outdoor kitchen of your dreams? Not me! Did you know that the “average” outdoor kitchen costs a whopping $13,000? One would think there has to be a DIY way to reduce that amount (at least a little).
Cabinetry is one of the larger expenses of an outdoor kitchen. With this in mind, I began researching how to decrease the cost of outdoor kitchen cabinets. While sifting through ideas, I came across the idea of building DIY pallet outdoor kitchen cabinets. Having previous experience building inexpensive rustic furniture and storage cabinets with pallets, I was intrigued. I sat down and began to break down the steps of how it could be done tastefully and not look like….. for lack of better words….a stack of pallets. In this guide, I will share my experience building with pallets and the steps I would take to transform ordinary pallets into unique and functional pallet outdoor kitchen cabinets.
Why Use Pallets?
Pallets are an excellent material for DIY projects because they are widely available and can be repurposed. They are also cost-effective as many businesses give them away for free or at a low cost. This makes them an excellent DIY building material because it won’t be very costly if you make a mistake. Also, by using pallets, you are saving money and helping reduce waste in the environment. Did you know that 95% of all wooden pallets are recycled today? You can contribute to this number with the pallets you use for this project!
The Challenge of Building with Pallets
There are some challenges you will likely encounter when building with pallets. First, pallets come in various shapes, sizes, and conditions. This can make it challenging to find pallets with similar wood color, thickness, and grain. In my opinion, this is what gives projects built with pallets their character and uniqueness. In raw form, pallets are typically not the most aesthetically pleasing material, so it requires some creativity and effort to make them look good. Lastly, pallet wood is usually rough and may have splinters or nails sticking out, so extra care must be taken during the building process.
Essential Materials and Tools for Your DIY Outdoor Kitchen Cabinets

Materials
- Wooden pallets (ensure they are heat-treated, no rot, and safe)
- Wood Screws
- Hinges
- Handles/knobs
- Outdoor wood sealant/paint
Material Tips: You can use nails to piece the project together but I find it easier to use screws. Keep in mind, if you ever need to replace a board, you will do less damage by backing a screw out.
Tools
I prefer to use a miter saw because it is easier to get accurate and smooth cuts. However, if you don’t have a miter saw, you can also use a circular saw, table saw, skil saw, or sawzall.
Impact Driver or drill with drill bits
Pallet Buster, Wrecking Bar, or a Flat Pry Bar (Best to get one with a long handle for leverage to pull up on boards)
Brush (For cleaning the pallets)
Safety Equipment
- Safety glasses
- Work gloves
- Dust mask
Tips for Sourcing High-Quality Pallet Wood Selection
Look for pallets stamped with “HT” for heat-treated, which means they are chemical-free.
Check local businesses or recycling centers for free or inexpensive pallets.
Avoid using pallets that have been exposed to chemicals or that show signs of mold or rot.
Pallet Preparation for Outdoor Kitchen Use
Cleaning and Sanitizing Pallets
The quickest way I have found to clean pallets is to use a pressure washer.
You can also scrub the pallets with a brush and warm, soapy water. Then, rinse thoroughly and allow them to dry completely by laying them out in the sun and/or under a fan.
Disassembling Pallets Safely
(It is very important to wear safety glasses during this process)
Use a pallet buster or wrecking bar to carefully disassemble the pallets. You will find very quickly that some pallets are made of harder wood than others which makes it very difficult to pull the nails out.
Remove all nails and screws to avoid damaging your tools or injuring yourself.
Sorting and Selecting the Best Wood Pieces for Your Pallet Outdoor Kitchen Cabinets
Select the strongest and most intact pieces for structural components. There are going to be some boards that are warped while while others will split or bust apart during the disassembly process. This is normal. It is unlikely that you will be able to use every piece of every pallet you take apart.
Use less perfect pieces for aesthetic (finish pieces) or less critical parts. During the disassembling process, I usually sort the boards into different piles. Your piles may be sorted into the categories of frame pieces, support pieces, finish pieces, and planking pieces.
Treating the Wood for Outdoor Durability

Sand all wood pieces to smooth out rough edges. If the pallets are very rough, it may be beneficial to start with a belt sander with a more aggressive grit sandpaper and then finish up with a palm or orbital sander with finer sandpaper to smooth it out.
Apply an outdoor wood sealant or paint to protect against moisture and pests. Some people prefer to seal all of the pieces before building the project – and this isn’t wrong.
I have tested sealing and painting before and after building. In my experience, I found that it is easier and more cost-efficient to seal or paint after the project is complete.
When I sealed or painted before building, I ended up wasting wood sealant and paint. This was because I had to cut the boards to different lengths and then discard the part I cut off. After all, I couldn’t use it anywhere else. There were also boards that I didn’t use at all. Basically, I was throwing sealed/painted pieces away which adds up both in time (applying) and money (sealant/paint) on larger projects. Also, when the project was finished, I had to go back and seal or paint the cut ends of the boards anyway.
It is best to apply sealant/paint after the cabinet part is built but prior to placing the countertop so you don’t get it on your countertop. Unless you plan to use pallet wood for the countertop also.
Designing Your Outdoor Kitchen Cabinet Layout
When designing your pallet outdoor kitchen cabinets layout, consider the following factors:
The size of your space: Measure the area where you plan to place your outdoor kitchen and take note of any obstacles such as trees or uneven terrain. You want to make sure you have enough room for all necessary features.
Your cooking needs: Think about what appliances you will need in your outdoor kitchen. Will you be grilling, baking, or using a stove? Make sure to leave enough space for each appliance and their corresponding power sources.
Your storage requirements: Consider how much storage you’ll need for utensils, plates, cookware, and other items. Plan different types of storage options such as cabinets and drawers
Measuring Your Outdoor Kitchen Space
Measure the area where you plan to install the cabinets.
Note down the dimensions carefully.
Planning Cabinet Dimensions and Configurations
Decide on the height, width, and depth of your cabinets. The width and depth will depend on the look you are going for as well as the area of installation. The typical counter height is 36 inches (3 feet) which includes the countertop thickness.)
Consider the number of cabinets needed to fit your space. This is where your creativity and vision come into play. Research some ideas before you start building so you know exactly what you are going for. You may want several small cabinets with single doors or you may want just a large cabinet with a couple of large double doors. Keep in mind, the more doors you have, the more knobs and hinges you will need which increases costs.
Sketching a Rough Design
Draw a simple layout plan on paper, including measurements and placement of doors, cabinet doors, and drawers. I typically draw two different views. The first is an aerial view as if I am looking down on the project from above. This allows me to visualize the total amount of floor space available and how long/wide the cabinets can be. The next is a frontal view which helps me visualize the height and width of the cabinet doors, the placement of frame supports, and where the cabinet hinges will attach.
Considering Ergonomics and Workflow
Plan for easy access to cooking areas and storage. Think about how you will be using your outdoor kitchen and design the layout accordingly. Consider placing cabinets near but not too close (due to fire hazard) to your grill for easy access to utensils and spices while cooking. Also, think about where you want to store frequently used items such as plates, glasses, and silverware to minimize trips back and forth from the indoor kitchen.
Ensure that the height is comfortable for food preparation. (36 inches is the standard height for kitchen countertops, but you may want to adjust based on your own height and preferences.)
Leave enough space between cabinets and appliances for comfortable movement. (A recommended minimum of 40 inches is suggested for walkways in a kitchen, but this can be adjusted based on personal preference and the size of your outdoor space.)
Step-by-Step Guide to Building Pallet Outdoor Kitchen Cabinets
Cutting Pallet Wood to Size
Now that you have your dimensions, it’s time to start cutting the pieces. I will break it down into sections.
Building the Top and Bottom of the Frame.
(Tip: In some cases, you may encounter very hard pieces of pallet wood that are difficult to start a screw into. I always keep a drill with a small bit handy so I can predrill the hole if this occurs.)
The base and the top of the frame are built the same way.
Make Stringers for the Length of the Base and Top
Using the stringer pieces of the pallet, lay them out parallel to each other for the length of your design for both the front and the back of the cabinet. You will likely need to place multiple stringers end-to-end to achieve the length of your cabinet.
After you have the stringer pieces placed end-to-end for the length of the cabinet for both the front side and back side, you may need to mark one of the stringers on either end and cut it to make the run of stringers match the exact length you need. After the cut, put it back in line with the others and it is time to tie the front and back runs of stringers together.
(Do this step for the front and back lines of stringers.) At each joint between the stringers, place a wood scab across the joint on the inside of the run and screw it into both stringers. I also recommend putting a couple of screws directly from one stringer into the other just for added support.
Now that your stringers for the length of the cabinet are tied together, it’s time to tie the front and back stringer runs together at each end.
Tie the Front Runs and Back Runs Together
Situate the long runs of stringers parallel to the width of your desired dimensions (measuring from the outside of one run to the outside of the other run at both ends).
Then, measure from the inside of the back run to the inside of the front run. Take that measurement and cut two more stringer pieces that are the same length.
Place those stringer pieces on the inside of the stringer runs at each end and screw them into the stringer runs. You should now have a rectangle shape.
Now let’s sturdy up this rectangle. Use the same measurement of the short piece you cut to tie the long runs together and cut some more stringer pieces to the same length.
Place them on the inside of the rectangle at intervals of about every two feet or so and screw them into the stringer runs.
You will repeat this process to make the top of the frame.
Preparing to Connect the Top and Bottom of the Frame
After you have completed the top and bottom parts of the frame, it’s time to connect them together for the height. For safety, this should be done with 2 or more people to hold the pieces while someone else puts screws in.
You need to make four runs of stringers measuring thirty-six inches (3 feet) in length. If you are using shorter stringers, it is important to use a very sturdy scab to connect the stringers together. Don’t forget to insert screws directly into the pieces at the joint to create an even more secure joint.
(Tip: If you are planning to use an actual countertop material, you will need to deduct the thickness of the countertop material from the thirty-six inches to keep the height of the counter at 3 feet)
Take the four stringer runs you have created and place them vertically on the inside of each end’s corners of the base. Then screw them into the base.
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Two Ways to Connect the Base and Top
Now to attach the top. There are two ways this can be done. (Warning: You will need multiple people to help for either way) Remember to practice safety first.
First Way
The first way is to leave the top on the ground. Pick up the base that the vertical stringers are already attached to and flip it over where the tops of the vertical stringers fit into the top the same way they are attached to the base.
Second Way
The second way is to pick up the top, hold it where the top of the vertical stringers are on the inside corners of each end and screw them in.
You should now have what looks like the frame of a box.
Next, look at the measurements for your cabinet and drawer openings. Cut additional vertical stringers at 36″ and screw them into the inside of the frame. Then, measure between the vertical stringers and cut pieces to complete the outline of the opening. It’s like you are outlining the dimensions of your cabinet doors while also continuing to sturdy the frame.
Adding Support Beams for Stability
Check the frame for sturdiness and stability. If you find areas that need more stability, you can:
Add horizontal and vertical support beams inside the frame for added stability.
These can be made from scrap pallet wood as they will not be seen from the outside.
Measure and cut the beams to fit between the frame pieces, attaching them with screws.
This will ensure that your cabinet is strong enough to support the weight of any items placed inside or on the countertop. As you are adding support beams for sturdiness, think about what type of countertop you are going to choose. Will it be a concrete countertop that is a heavier material or will it be a wood top that is lighter. This will give you an idea of how many support beams you should put in place.
Planking the Walls of the Cabinets
Once your frame and support beams are secure and you have added support beams where needed , it’s time to add the planking for the walls of your cabinet.
Measure and cut pallet wood pieces to fit vertically or horizontally (depending on your preference) between the top and bottom frames. Attach them from the inside using screws.
For added strength and durability, you can also add a layer of plywood or another sturdy material behind the planks.
You can use the same method for the countertop.
Creating Door Frames and Drawer Boxes
Measure and cut wood pieces to form the frame for doors and drawers.
Attach the frame to the front of your cabinet using hinges for doors and drawer slides for drawers.
Measure and cut planks to fit inside the door frames or as a base for your drawer boxes.
Attach these planks with screws, making sure they are evenly spaced and aligned with the edges of the frame.
For added support, you can also add vertical support beams inside the door frames or under the drawer boxes.
Assemble these frames and attach them to the main cabinet structure using screws.
Installing Shelves and Storage Solutions
Adding Adjustable Shelving
Install shelf brackets inside the cabinet. These can be attached to the support beams or side walls of the cabinet.
Cut pieces of pallet wood, or other materials to fit on top of the brackets and act as shelves.
Attach these shelves to the brackets with screws, making sure they are level and secure.
To make your shelves adjustable, you can also use shelf pins or pegs that can be inserted into pre-drilled holes on each side of the cabinet.
Incorporating Storage Solutions
Evaluate your storage needs and decide on the best solutions for your cabinet.
You can add hooks for hanging pots and pans on the sides of your cabinet, or create a spice rack using small planks of wood.
Another option is to install sliding racks or baskets inside the cabinet for easy access and organization.
Utilize the space on top of your cabinet by adding a shelf or attaching hooks for hanging lightweight items like kitchen towels.
Consider incorporating pull-out drawers or bins underneath the cabinet for additional storage space.
Creating Pull-Out Drawers from Pallet Wood
Use wood pieces to construct drawer boxes.
Cut pieces of pallet wood to fit onto the front of the drawer box, creating a rustic look.
Attach these pieces using screws.
Install drawer slides on the bottom edges of the box and on the inside of the cabinet.
Add handles or knobs for easy pulling and sliding.
Incorporating Clever Storage Hacks
Add hooks, racks, or small shelves inside the cabinets for utensils and appliances.
Attach a magnetic strip to the inside of a cabinet door for storing knives or other metal utensils.
Use stackable bins or baskets to optimize vertical space and keep items organized.
Adding a Countertop to Your Cabinets
Measure and cut the countertop material to fit the top of the cabinets.
Use adhesive or screws to secure the countertop onto the cabinets.
Add caulk along any gaps between the countertop and cabinets for a seamless finish.
Weatherproofing Your DIY Pallet Outdoor Kitchen Cabinets
Choosing the Right Outdoor Finish or Paint
Select a durable outdoor paint or finish that matches your aesthetic.
Consider using marine-grade finishes for extra protection against water and weather damage.
Apply multiple coats of finish or paint, following the manufacturer’s instructions.
Applying Sealants for Moisture Protection
Apply two to three coats of sealant to all wood surfaces.
Allow each coat to dry thoroughly before applying the next.
Installing Weather Stripping on Doors and Drawers
- Add weather stripping to the edges of doors and drawers to prevent moisture entry.
Tips for Maintaining Your Pallet Cabinets Year-Round
Regularly check for damage or wear.
Reapply sealant annually to maintain protection.
Adding Finishing Touches to Your Outdoor Pallet Kitchen Cabinets
Installing Hardware
Attach handles, knobs, and hinges to doors and drawers.
Ensure all hardware is securely fastened.
Incorporating Lighting Solutions
Add LED strip lights or battery-operated puck lights inside cabinets for visibility.
Install solar-powered outdoor lights around the perimeter of your kitchen for ambiance and functionality.
Decorative Ideas to Personalize Your Cabinets
Paint or stencil designs on the cabinet doors.
Add decorative trim or molding.
Hang a chalkboard or corkboard on the inside of cabinet doors for organization.
Install hooks or racks for hanging utensils or pots and pans.
Conclusion
Congratulations, you have successfully repurposed pallet wood into functional and stylish cabinets for your outdoor kitchen! Not only is this a great way to save money, but it also helps reduce waste by giving new life to old materials. So keep exploring and repurposing materials to create unique and sustainable pieces for your outdoor area. Don’t be afraid to think outside the box and try new things – you never know what kind of amazing creations you can come up with! And most importantly, have fun with it. Building something yourself is always a rewarding experience, especially when it’s something that will be used and appreciated in your everyday life. Enjoy your new pallet outdoor kitchen cabinets!
Frequently Asked Questions
Does pallet wood hold up outdoors?
Pallet wood is a durable and weather-resistant material that can hold up well outdoors, especially when properly treated and maintained. However, it’s important to note that pallets may have been exposed to chemicals during their previous use for transportation. It’s recommended to sand, seal, and finish the wood before using it in any outdoor project.
How do I maintain my pallet outdoor kitchen cabinets?
Regularly clean your pallet wood cabinets with a mild soap and water solution, then rinse and dry thoroughly. To protect the wood from harsh elements, apply a weatherproofing sealant or paint. You may also want to periodically inspect the hardware and tighten any loose screws or bolts.
Do you have to sand pallet wood?
Sanding pallet wood is not always necessary, but it can improve the appearance and smoothness of the wood. It also helps to remove any rough edges or splinters, making it safer to work with. If you’re planning on painting or staining your pallet wood, sanding is highly recommended for a smoother finish.
Are there any safety precautions when working with pallet wood?
It’s important to take proper safety precautions when working with pallet wood, as it may contain nails, staples, and other potential hazards. Before using pallets for any DIY projects, make sure to inspect them thoroughly and remove any protruding objects. It’s also recommended to wear protective gear such as gloves and goggles while handling the wood.
What grit sandpaper to use on pallet wood?
The grit of sandpaper you use on pallet wood will depend on the condition and desired finish of the wood. If the wood is in good condition, a medium or fine grit (around 120-220) may be sufficient. However, if it’s rough or has splinters, starting with a coarser grit (around 80-100) and gradually moving to a finer grit can help achieve a smoother surface. It’s best to test different grits on a small area first before sanding the entire piece. Additionally, using an orbital sander can make the sanding process quicker and more efficient.
How can you tell if a wooden pallet is rotten?
When inspecting wooden pallets, look for any signs of rotting such as discoloration, soft spots, or a musty smell. If the wood is visibly decaying or crumbling, it’s best to avoid using it for any projects. It’s also important to check for mold on the wood, as it can be potentially harmful if inhaled.
Is it necessary to seal pallet wood?
Sealing pallet wood is not necessary, but it can provide added protection and enhance its appearance. If you plan on using the pallet wood outdoors or in a high-traffic area, sealing it with a polyurethane or wax can help prevent moisture damage and make it easier to clean. It can also bring out the natural color and grain of the wood, giving it a more polished look. However, if you prefer the rustic and weathered appearance of untreated pallet wood, then sealing is not necessary.