I made this tray from pallet wood from used wood pallets I harvested. It took about 3 days.
Day 1:
- Disassembled 1 pallet. Used Ryobi 18V OnePlus (One+) cordless power tools. I love those Ryobi’s. These aren’t even the brushless ones, but with the 4HP battery they are sufficient for the job.
- Glued the pallet planks together (with wood glue) and clamped down to my Worx collapsible workbench.
Day 2:
- This was done in an hour or so before I had to be at work.
- Sanded glued boards.
- Began rounding corners and softening edges with belt sander.
- Cut two 1-inch strips of pallet wood and glued to top as edges and handles. I would not have connected these, except that they were needed to give the glued planks stability. Nailed strips to base with Ryobi cordless nailgun.
Day 3:
- Brad nails were too long so I used wire cutters to snip most of the excess, then used rasps and files to grind away and file flush the rest of the nails.
- Continued sanding the entire tray with Ryobi tools (Random orbital sander and Multi-tool with triangle sander bit.
- Finished rounding edges and smoothing corners.
- Oiled entire surface with paper towels and mineral oil.
Below are some photos of this project:
