How to Build a Pallet Fort

Let’s face it. We’ve all spend a solid amount of our childhood building forts, tents and teepees out of pallets. Picnics, sleepovers and entertainment for kids has been for the past 40 years or so at the expense of the companies storing their pallets outside their warehouses. When I see a pallet I’m always reminded of my childhood so that whenever I see one these days, I have an urge to build something from it. Whether is a fun new project or even just something that makes my wife happy like storage for shoes in our bedroom, there’s almost always something you can do with a pallet. This summer I noticed there’s been a lot more attention paid to this topic on some major home improvement internet sites. It got me to thinking that lots of people are probably already aware of the concept but may not know where they can get their groove on and start building stuff. So here are the best places to go if you’re looking for free pallets in the Seattle area.

A pallet fort is pretty much everything a child could want in a play fort. It’s big, it’s cool, and it’s something that adults can look back on fondly. How can you build a fort using recycled materials? Read on to find out…

Item	Details
Shipping Pallets	Cost: Typically free Durability: Built to hold heavy loads Ease of Use: Simple to manipulate and modify
Construction Applications	Simple Forts: Great for outdoor play Playhouses: Can be customized for children’s use
Pallet Dimensions	Vary by Company: Different companies have different sizes Interchangeable Use: Similar design allows for interchangeability
Building Instructions	Materials Needed: Two stacks of four pallets each Placement: Stacks side by side with tops facing inward Height Requirement: Additional layers needed until at least 6 feet tall

Shipping Pallet Dimensions

🛠️ What This Is About
Upcycling shipping pallets into a kids’ fort or playhouse—an easy, fun backyard project using reclaimed wood that’s both creative and budget-friendly.

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📏 Standard Pallet Dimensions

• Most North American pallets are 48″ × 40″, commonly known as GMA pallets.
• Ship crates often measure about 47″ × 39″ × 24″, providing ~3 cubic feet (≈ 50 lb capacity).
• Other sizes you might encounter include 42×42 and 48×48.

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📋 Materials or Tools Needed

• Pallets: 2–10 ft long depending on desired size
• Fasteners: wood screws or nails
• Tools: hammer, drill/driver, saw, crowbar
• Finishing supplies: sandpaper, sealant or varnish (to remove splinters and seal unregulated wood)

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⚙️ Step‑by‑Step Instructions

1. Gather and prep pallets
   • Choose good pallets, remove nails/staples with a crowbar and hammer.
2. Design your layout
   • Decide fort size (e.g., two pallets wide, one pallet deep, one pallet tall).
3. Disassemble boards (optional)
   • You can use full pallets for walls, or break them down for plank walls, roof, deck.
4. Build the base and frame
   • Screw pallet planks together to form a stable floor. Build side frames from beams.
5. Attach walls
   • Secure full pallets or planks vertically/horizontally to frames.
6. Add roof or porch (optional)
   • Use additional pallet boards and scrap plywood like a playhouse build.
7. Finish and protect
   • Sand rough edges well. Seal all wood with spar urethane or outdoor varnish—critical for safety.

✅ Pros and Cons

Pros	Cons or Considerations
✅ Upcycles free materials	⚠️ Pallet wood may harbor bacteria or chemicals
✅ Cheap/fun project	⚠️ Needs sanding and sealing to be safe
✅ Customizable size and design	⚠️ Requires basic tools and effort

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💡 Common Mistakes to Avoid

• Not sanding and sealing—splinters or toxicity risks.
• Using broken pallets—inspect before building.
• Skipping level/foundation steps—fort may wobble on rough ground.

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👷 Who Should Use This

• Parents or DIYers wanting a quick, low-cost play structure.
• Folks comfortable working with tools and reclaimed wood.
• Anyone aiming for a creative backyard project over a weekend.

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🧰 Expert Tips

• Coat wood with spar urethane or varnish for weather and hygiene protection.
• Sand thoroughly to avoid splinters for kids.
• Use sturdy pallets and reinforce corners with extra screws or blocks.

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📌 Quick Checklist

• Select 2–5 sound pallets
• Disassemble or use whole boards
• Build a solid, level floor base
• Frame and attach walls
• Add roof or partial cover
• Sand smooth and seal all wood
• Final inspection: no protruding nails or sharp edges

How to Make a Pallet Fort

1. Get Supplies: You’ll need some cardboard boxes and shipping pallets for this project. The size of the boxes will vary depending on how big you want your fort to be, but if you’re using full-sized shipping pallets like we did, it’s best to use large cardboard boxes like ones that might hold televisions or large appliances. If you’re using smaller boxes, you may want to cut them down so they’re not so heavy when stacked together. The best part about this project is that it costs less than $20!

2. Gather Your Supplies: Lay out all of your supplies on the ground in front of where you want your fort to go (such as outside) or choose an indoor location if it’s raining outside or too cold outside for kids (or adults!). Make sure there’s plenty of room around each box so that when you stack them up, there’s enough space between each layer for kids (or adults) to walk through without

A pallet fort is a fun and easy way to make a fort or playhouse for children. The best part is that you can easily buy a few pallets at your local home improvement store, cut them up and make a custom-sized fort for your child.

Here’s how:

1. Purchase a pallet from your local home improvement store. You can usually find them in the lumber section or on the side of the building near the dumpster area.

2. Cut the boards off of one side of the pallet with a circular saw or reciprocating saw (if you have access to one). You’ll need to cut through both layers of wood on each side of the board so it will be easier if you use an electric saw like this one from Ryobi.

3. Draw out a design on paper that includes windows, doors and other features needed for your fort (if desired). This will help you determine how many boards need to be removed from each side of the pallet so that you end up with an evenly sized square or rectangle when finished cutting out all four sides of the pallet (don’t forget about making room for windows and doors!).

4. Remove all boards from one side using either circular saws (if using multiple

To build a pallet fort, you’ll need:

A few pallets

A saw or other cutting device

Hammer and nails

A drill or screwdriver (optional)

Step 1: Cut the pallets into pieces. The exact size of the pieces depends on what you want to make and how much space you have. The image above shows two boxes made from one full-sized pallet. You could also make a smaller box or just a platform if you don’t have room for anything else. The important thing is that each piece should be big enough to support the weight of whatever will be placed on top of it (and possibly people).