A typical standard shipping pallet measures 48 inches long by 40 inches wide by 5 inches tall. The slats on the pallet measure about 4 inches wide. These dimensions make pallets the perfect medium for building your own Adirondack chair for your yard or patio. To do this, you'll need to determine the width and length for the chair; a good example is 26 inches by 48 inches. You can make an Adirondack chair with a used pallet or by ordering one new.
Disassemble your wooden pallet with a pry bar or a hammer. Remove the nails that were used to secure the pieces together. You should have two 48-inch long pieces and 16 slats that measure 40 inches each.
Measure one slat of the pallet to 14 inches with the tape measure. Cut the slat to this length with a miter saw. Measure and cut the remaining section of the slat to 14 inches. Set these aside for use later.
Cut a second pallet slat into two 20-inch pieces. Set the pieces aside for use later. Cut six slats to a length of 26 inches each.
Position the two 48-inch pieces of the pallet side by side, 26 inches apart. Set the first 26-inch slat on top of the two pieces at one end. Drill two pilot holes into the wood on each side with the power drill. Secure the slat with screws. Set and secure an additional four slats 1/2 inch apart.
Measure 3 1/2 inches from the left edge of the fifth slat. Make a mark on each side of the frame. Set the remaining 26-inch slat on the mark. Drill pilot holes and secure with screws.
Measure and cut four slats to a length of 25 inches each. Place the two pieces you cut to equal lengths in Step 3 on the ground side by side, 25 inches apart. Secure three slats 1/2 inch apart by drilling pilot holes and using screws. Turn the piece over and secure the remaining slat to the end. This will be the back for the chair.
Insert the back of the chair into the 3 1/2-inch gap in the chair frame. Angle the pieces of wood so each side is resting on one side of a pallet slat. Drill a hole into the wood and then insert a bolt. Tighten a nut onto the bolts with the wrench.
Cut a 45-degree angle onto the end of the 14-inch pieces that you cut earlier with the miter saw. Lift the left side of the chain and attach the 14-inch pieces to the sides for the legs.
Sand the surface of the chair with the sandpaper. Apply a coat of paint or varnish to protect the wood from the elements.