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Table of Contents
- Tools, Supplies, PPE, and Steps
- Making The Rustic Pallet Wood Shutters
- I Love Rustic Pallet Wood Shutters!
Rustic pallet wood shutters are one of the easiest things you can make with reclaimed pallet wood.
In this article, I’ll tell you how I make shutters that are used for non-functioning interior wall decor. These shutters are also featured on The Home Depot Blog.
- Related Article: DIY Candlesticks Made From Pallet Wood
Tools, Supplies, PPE, and Steps
I’ve linked to several different retailers below for your convenience. I encourage you to shop around as I’ve found that each item may sell for less at a different retailer.
Tools
DEWALT 12″ Double Bevel Sliding Compound Miter Saw
DEWALT Rolling Miter Saw Stand
DEWALT 16-Gauge Brad Nailer
DEWALT Angle Grinder
DEWALT Hammer
Stanley Pry Bar
Klein Diagonal Pliers
DEWALT Tape Measure
(Optional) Paint Brush
Carpenter Pencil
Supplies
(Optional) Rust-Oleum Chalked Paint Linen White
(Optional) Rust-Oleum Chalked Protective Topcoat
Sawtooth Picture Hangers
Gorilla Wood Glue
Gator 120 Grit Sand Sheet
Pallet Wood
Personal Protective Equipment
Firm Grip Flex Impact Gloves
RZ Mask Dust Mask
3M Safety Glasses
3M Earmuff
Related Article: PPE: DIYers Should Use Personal Protective Equipment
Steps
Time needed: 2 hours.
How To Make DIY Rustic Pallet Wood Shutters
- Pick the pallets and dismantle them. We’re only using the decking, not the stringers.
- If you want to keep any nails, cut them off from the back of the boards and grind down any stubs sticking out.
- Cut the boards to the desired lengths.
- Lightly sand the entire surface of the boards and round off all the board edges.
- Add a bead of Gorilla wood glue to the back of top and bottom rail boards, then nail them to the three stile boards.
- (Optional) Paint the shutters with Rust-Oleum Linen White Chalked paint.
- (Optional) Complete finishing by applying Rust-Oleum Chalked Protective Topcoat.
Making The Rustic Pallet Wood Shutters
I only use reclaimed pallet decking when I make these shutters. I pick out boards that have splits, cracks, knots, rough saw marks, and even water stains. The more distressed, the better!
Measurements
The measurements for these shutters as pictured are 17″ W x 24″ H x 1 3/4″ D.
Sanding
Not much sanding is needed for these shutters. Use a 120 grit sanding sheet and lightly sand the front and back surfaces. I also sand the board edges to round them off.
I try to keep as many nails as possible in the pallet wood because the nail heads add nicely to the rustic look. Turn the boards over, cut the nails as close to the wood as possible, then grind them flush to the wood.
Assembly
Once the boards are cut, lay the three stile boards down, glue the back of the top and bottom rail boards, and lay the rail boards on the front of the stile boards.
Nail the rail boards to the stile boards. You could also screw into the rail boards from the back of the three stile boards; just be sure to drill pilot holes for the screws.
Paint
You can paint the shutters or simply leave the wood in its natural state. For the painted versions, I use Rust-Oleum Linen White Chalked paint, then Rust-Oleum Chalked protective topcoat.
I Love Rustic Pallet Wood Shutters!
I absolutely love the distressed look pallet wood. If you’re looking to make your own shutters, I hope this article has given you plenty of inspiration!
